TWI558567B - Fiber reinforced shaped body and method for producing the same - Google Patents

Description

Fiber reinforced molded body and method of producing the same

The present invention relates to a fiber-reinforced molded article obtained by laminating a fiber-reinforced material and a surface material on at least one surface of a core material, and a method for producing the same.

In recent years, a fiber-reinforced molded body has been proposed as a member requiring high rigidity such as a casing of a notebook computer. The fiber-reinforced structure is, for example, a carbon fiber-reinforced body obtained by laminating a carbon fiber prepreg and reacting and curing it. Examples of the fiber-reinforced molded article using carbon fibers include the following.

Patent Document 1 discloses a fiber-reinforced molded article in which a plurality of fiber-reinforced layers of a plurality of layers are laminated in a specific arrangement direction, and the fiber-reinforced layer is formed by arranging continuous fibers of carbon fibers in a sheet shape in one direction.

Patent Document 2 discloses a sandwich structure including a core material having a void and a fiber reinforced material comprising continuous carbon fibers and a matrix resin disposed on both surfaces of the core material.

Patent Document 3 discloses that a sheet in which a continuous fiber reinforced fabric containing at least carbon fibers is disposed on both surfaces of a soft member layer is provided in an injection molding die, and a composite resin component is formed on a side portion of the sheet. Molded product.

Further, in Patent Document 4, as a method for producing a sandwich type composite material having elasticity, a fabric sheet comprising a glass fiber impregnated with an epoxy resin is disposed above and below a mold to form an amine between the fabric sheets. Method of urethane resin foam (Example 1 of Patent Document 4).

However, as shown in Fig. 8, the fiber-reinforced molded body having a fiber fabric such as a carbon fiber woven fabric or a glass fiber woven fabric on the surface thereof has a step difference between the fiber overlapping portion 215 and the portion of the woven eye gap 216 on the surface of the molded body. As a result, the surface roughness of the surface is increased by the influence of the step, and even if the appearance coating is applied, the influence by the step difference cannot be reduced, and it is difficult to obtain a smooth surface. Symbol 221 denotes a transverse fiber and 222 denotes a longitudinal fiber.

Further, when the appearance coating is applied, bubbles may remain in the step portion, and pinholes may be formed on the surface of the coating film. In particular, in terms of improving the appearance and the like, when the appearance is applied in general use, the appearance state in the case of applying the appearance is important. Further, in general, inorganic substances such as carbon fibers have poor compatibility (adhesiveness) with a urethane coating material or a UV (Ultraviolet) coating material, and the coating film is peeled off.

[Previous Technical Literature] [Patent Literature]

[Patent Document 1] Japanese Patent Laid-Open Publication No. 2004-209717

[Patent Document 2] WO2006/028107

[Patent Document 3] Japanese Patent Laid-Open Publication No. 2007-038519

[Patent Document 4] Japanese Patent Laid-Open No. Hei 01-163020

The present invention has been made in view of the above aspects, and an object thereof is to provide a fiber-reinforced molded body having a surface roughness before application, a good appearance when coated, and no peeling of a coating film and Production method.

In view of the above, according to the present invention, a fiber-reinforced molded article comprising a core material, a fiber-reinforced material laminated on at least one side of the core material, and a surface laminated on the fiber-reinforced material can be provided. And the fiber material is integrated with the fiber reinforcing material and the surface material; and the fiber reinforcing material has a fiber woven fabric and a hardened thermosetting resin impregnated in the fiber fabric, the surface material a porous sheet having continuous cells and having a number of micropores of 8 to 80/25 mm, and the above-mentioned thermosetting resin impregnated in the porous sheet, wherein the surface roughness Rz of the surface material is Below 30 μm.

In the above fiber-reinforced molded product, the porous sheet may be a resin foam.

In the fiber-reinforced molded product, the resin foam may be a urethane resin foam.

In the fiber-reinforced molded product, the resin foam may be a urethane resin foam from which a microporous film is removed.

In the above-mentioned fiber-reinforced molded product, the core material includes a member for a core material having continuous cells, and a thermosetting resin for core material impregnated in the core member, and the core material and the fiber reinforcement are used. The material and the surface material described above can be integrated by using the thermosetting resin and the thermosetting resin for the core material.

In the fiber-reinforced molded product, the thermosetting resin for a core material may be the same as the thermosetting resin.

In the fiber-reinforced molded product, the fiber reinforcing material may be laminated on both surfaces of the core material, and the surface material may be laminated on at least one surface of the fiber reinforcing material.

In the above fiber-reinforced molded product, the core material may include a plurality of members for a core material.

In the fiber-reinforced molded product, a coating film is provided on the surface of the surface material, and the surface roughness of the coating film is 25 μm or less.

Moreover, according to the present invention, there is provided a method of producing a fiber-reinforced molded article, which is characterized in that a core material comprising a member for a core material is laminated, and a fiber reinforced with a fiber fabric laminated on at least one side of the core material is produced. And a method of producing a fiber-reinforced molded article having a surface material of a porous sheet laminated on the fiber-reinforced material; the method of manufacturing comprising the step of impregnating the core material with a thermosetting resin And at least one of the member and the fiber fabric; and a laminating step of sequentially laminating the fiber fabric and the number of micropores of at least one surface of the core member for 8 to 80/25 mm and a thickness of 0.4~ a 3.0 mm porous sheet having continuous cells; and a compression heating step of heating the surface of the core member, the fiber fabric, and the porous sheet while compressing The resin is impregnated into the core member, the fiber woven fabric, and the porous sheet, and is cured to cause the core material, the fiber reinforced material, and the surface Integration.

In the method for producing a fiber-reinforced molded product, the fiber-reinforced material may be laminated on both surfaces of the core material, and in the impregnation step, the resin ratio R defined by the following formula (B1) is in the range of 50 to 80%. In the above-described layering step, at least the layer of the fiber fabric is laminated on the other surface of the core member, and in the compression heating step, the lower portion is formed by impregnating the core material member with the thermosetting resin. In the state in which the compression ratio C defined by the formula (A1) is in the range of 200 to 5000%, the thermosetting resin is cured in a state where the core member is compressed, and the flexural modulus of the fiber-reinforced molded article is set to 30. Above GPa,

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

R=(Wb-Wa)/Wb×100 (B1)

(Wa: the total weight of the core material member, the fiber woven fabric, and the porous sheet, Wb: the total weight of the core member, the fiber woven fabric, and the porous sheet after impregnating the thermosetting resin, R: resin ratio).

In the method for producing a fiber-reinforced molded article, the compression ratio of the member for a core material can be set to 1000 to 2600%.

In the method for producing a fiber-reinforced molded product, the porous sheet may be a porous sheet comprising a urethane resin foam from which a microporous film is removed.

In the method for producing a fiber-reinforced molded article, in the impregnation step, the thermosetting resin containing the same material may be impregnated into both the core member and the fiber fabric.

In the method for producing a fiber-reinforced molded article, in the stacking step, a prepreg in which the fiber fabric impregnated with the thermosetting resin and the porous sheet are laminated to form the fiber fabric and the above The prepreg is laminated on the core member for contact with the core member.

In the method for producing a fiber-reinforced molded article, in the stacking step, two prepregs in which the fiber fabric impregnated with the thermosetting resin and the porous sheet are laminated may be prepared to make one of the above-mentioned pre-pregs The fiber fabric of the impregnation body is in contact with the member for core material, and the porous sheet of the other prepreg is brought into contact with the member for the core material, respectively, on both sides of the member for core material The above prepreg is laminated.

Moreover, according to the present invention, it is possible to provide a fiber-reinforced molded product comprising a core material comprising a core material member having continuous cells, and a fiber reinforcing material laminated on both sides of the core material and having a fiber fabric. And a surface material having a porous sheet material laminated on at least one surface of the fiber reinforcing material, and the core material, the fiber reinforcing material, and the surface material are integrated by a thermosetting resin; and the core The material is obtained by impregnating the above-mentioned core material member with the thermosetting resin and curing the thermosetting resin in a state where the core material member is compressed, and the compression ratio defined by the following formula (A1) When C is in the range of 200 to 5000%, the resin ratio R of the thermosetting resin specified by the following formula (B1) is in the range of 50 to 80%, and the flexural modulus of the fiber-reinforced molded article is 30 GPa or more.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

R=(Wb-Wa)/Wb×100 (B1)

(Wa: the total weight of the core material member, the fiber woven fabric, and the porous sheet, Wb: the total weight of the core member, the fiber woven fabric, and the porous sheet after impregnating the thermosetting resin, R: resin ratio).

Further, according to the present invention, there is provided a method for producing a fiber-reinforced molded article, which comprises producing a core material comprising a member for a core material, laminating on both sides of the core material, and containing a fiber reinforcement having a fiber fabric And a method of laminating a fiber-reinforced molded body comprising at least one surface of the fibrous reinforcing material and comprising a surface material of a porous sheet having continuous cells, the manufacturing method comprising the steps of: impregnating a step, which is thermosetting a resin impregnated into at least one of the member for core material and the fiber fabric; and a laminating step of laminating the fiber fabric on both sides of the core member and laminating on at least one side of the laminated fiber fabric The porous sheet; and a compression heating step of heating the thermosetting resin to the core material by heating against the core member, the fiber fabric, and the porous sheet The member, the fiber woven fabric, and the porous sheet are hardened to cause the core material and the fiber reinforced material and The surface material is integrated; the impregnation in the impregnation step is carried out so that the resin ratio R defined by the following formula (B1) is in the range of 50 to 80%, and the compression in the compression heating step is as follows (A1) The compression ratio C is 200 to 5000%, and the compression is performed.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

R=(Wb-Wa)/Wb×100 (B1)

(Wa: the total weight of the core material member, the fiber woven fabric, and the porous sheet, Wb: the total weight of the core member, the fiber woven fabric, and the porous sheet after impregnating the thermosetting resin, R: resin ratio).

According to the fiber-reinforced molded product of the present invention, the surface material is formed by a capillary phenomenon in which a thermosetting resin is infiltrated into a porous sheet having continuous cells and having a number of micropores of 8 to 80/25 mm. Therefore, the thermosetting resin easily oozes out to the surface by the continuous bubbles, and thus the smoothing surface is formed by the thermosetting resin which bleeds out to the surface of the surface material. Thereby, the surface roughness of the surface material can be made 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and a good appearance can be obtained.

Moreover, since most of the smooth surface is a thermosetting resin which oozes out from the porous sheet, it is integrated with the fiber-reinforced molded body and does not peel off together with the coating film. Moreover, since the adhesion between the thermosetting resin and the coating film is high, the fiber-reinforced molded article of the present invention exhibits good coating film adhesion.

Moreover, according to the method for producing a fiber-reinforced molded article of the present invention, a fiber-reinforced molded article excellent in the above-described external appearance can be easily obtained.

Moreover, according to the fiber-reinforced molded product of the present invention, the resin ratio R can be set to 50 to 80%, and the compression ratio C can be set to 200 to 5000%. Therefore, since the core material is filled with the thermosetting resin without a gap and densely, a fiber-reinforced molded body having sufficiently high rigidity even if it is thinned can be obtained. In addition, since the surface material contains a porous sheet having continuous cells, the thermosetting resin which has been oozing out from the porous sheet by capillary action is surface-hardened, whereby a fiber-reinforced molded body having a smooth surface and excellent appearance can be obtained. .

Moreover, according to the method for producing a fiber-reinforced molded article of the present invention, a fiber-reinforced molded article having high rigidity and excellent appearance can be easily obtained.

Hereinafter, a fiber-reinforced molded product according to an embodiment of the present invention will be described with reference to the drawings.

The fiber-reinforced molded product 10 according to the embodiment of the present invention shown in Fig. 1 includes a core material 11, a fiber-reinforced material 21 laminated on both surfaces of the core material 11, and a fiber laminated on one side of the core material 11. The surface material 25 integrated on the surface of the reinforcing material 21 is applied to the surface of the surface material 25 and used for a casing of a mobile device such as a notebook computer.

Further, in the illustrated example, in the fiber-reinforced molded product 10, the fiber-reinforced material 21 and the surface material 25 are laminated on the core material 11 only on the side A where the coating is applied, and the side B which is not coated is applied. Only the fiber reinforcing material 21 is laminated without laminating the surface material 25. However, depending on the use of the fiber-reinforced molded product 10 or the like, the side B which is not coated may not be laminated with both the fiber reinforcing material 21 and the surface material 25. Moreover, in the application for coating on both sides of the fiber-reinforced molded product 10, it is preferable that the surface material 25 is laminated on the surface of the fiber-reinforced material 21 on both sides of the core material 11 and integrated.

The fiber-reinforced molded product 10 is a plate-shaped member of a specific size. The thickness of the fiber-reinforced molded product 10 is preferably 0.3 to 2.0 mm, and the flexural modulus (JIS K 7074-1988 A method) is preferably 30 GPa or more, 60 GPa or less, and more preferably 35 GPa. Above, below 55 GPa. Moreover, the specific gravity is preferably 1.2 or more and 1.5 or less, and more preferably 1.28 or more and 1.35 or less.

If the thickness is less than 0.3 mm, rigidity is not easily obtained, and on the other hand, when the thickness is thicker than 2.0 mm, the mobile device as a whole becomes thick. In the case where the fiber-reinforced molded product 10 is used as a casing of a mobile device, the side wall of the casing or the like can be appropriately vertically placed at a specific surface position by so-called injection molding such as injection molding.

It is preferable that the core material 11 has a sheet-shaped member for a core material, and in particular, a thermosetting resin (thermosetting resin for a core material) is impregnated into a resin foam for a core material having continuous cells and cured. The material of the member for a core material is not particularly limited, and for example, it may be selected from a thermosetting resin foam such as a urethane resin foam or a melamine resin foam. In the case where flame retardancy is required for the fiber-reinforced molded product 10, it is preferred that the member for a core material has flame retardancy. In this respect, since the melamine resin foam has good flame retardancy, it is suitable as a member for a core material.

Furthermore, it is preferable that the core material 11 is obtained by curing the core material with a thermosetting resin in a state where the core member is compressed. When the core material is cured by the thermosetting resin in a state in which the core material member is compressed, the thinning and rigidity of the fiber-reinforced molded product 10 can be improved. Further, the degree of compression is preferably such that the thickness of the fiber-reinforced molded product is 0.3 to 2.0 mm at the time of production of the fiber-reinforced molded article described below.

The original thickness of the member for core material differs depending on the compression ratio. For example, in the case of obtaining a fiber-reinforced molded body having a thickness of 2 mm or less, the original thickness is preferably 1 to 25 mm. If the original thickness is in this range, the thermosetting resin for the core material having a suitable amount can be impregnated, and the yield after heating and compression is also good.

When the original thickness is thinner than 1 mm, the core material to be impregnated with the thermosetting resin cannot be held in the core member, and the resin ratio is not uniform, so that the bending elastic modulus (rigidity) is lowered. When the original thickness is thicker than 25 mm, in the case of obtaining a fiber-reinforced molded body having a thickness of 2 mm or less, compression is difficult, and a fiber-reinforced molded body having a uniform thickness cannot be obtained. Further, in terms of ease of compression, impregnation, lightness, and rigidity, the member for a core material preferably has a density of 5 to 80 kg/m ³ before compression.

The material of the thermosetting resin for the core material is not particularly limited, and in order to increase the rigidity of the fiber-reinforced molded body 10, it is necessary to have a certain degree of rigidity, and it is optional to use an epoxy resin, a phenol resin, an epoxy resin, and a phenol resin. Among the groups of mixtures. Moreover, when the flame-retardant property is required for the fiber-reinforced molded product 10, it is preferable that the thermosetting resin for core materials has flame retardancy. Phenolic resins are preferred because of their good flame retardancy.

The fiber-reinforced material 21 is formed by impregnating a thermosetting resin (thermosetting resin for reinforcing material) with a fiber woven fabric and curing it. Examples of the fiber woven fabric include glass fibers, carbon fibers, and the like. In particular, the carbon fiber woven fabric is preferred as a fiber woven fabric because it is excellent in light weight and high rigidity. Further, the fiber fabric is preferably a fabric in which the fibers are not only in a single direction, and for example, a plain weave composed of warp and weft, a twill weave, a satin weave, and a triaxial fabric composed of yarns in three directions are preferable. Further, in the case where a carbon fiber woven fabric is used as the fiber woven fabric, the carbon fiber woven fabric preferably has a fiber weight of 90 to 400 g/m ² in terms of impregnation and rigidity of the thermosetting resin.

The thermosetting resin for a reinforcing material is not particularly limited. However, in order to increase the rigidity of the fiber-reinforced molded product 10, it is necessary to have a certain degree of rigidity, and it may be selected from a mixture of an epoxy resin, a phenol resin, an epoxy resin and a phenol resin. Among them. Moreover, when the flame-retardant property is required for the fiber-reinforced molded product 10, it is preferable that the thermosetting resin for reinforcing materials has flame retardancy. Since phenol resin has good flame retardancy, it is suitable as a thermosetting resin for reinforcing materials. Further, the thermosetting resin for the core material and the thermosetting resin for the reinforcing material may be thermosetting resins of the same material.

In addition, when a melamine resin is used as the resin foam for the core material 11 and a phenol resin is used as the thermosetting resin for the core material and the thermosetting resin for the reinforcing material, the flame retardant can be obtained without using a flame retardant. A fiber-reinforced molded article having a sufficiently flame-retardant shape in a casing of a mobile device such as a notebook computer is preferred.

In addition, the amount of all the thermosetting resin including the thermosetting resin for core material and the thermosetting resin for reinforcing material in the entire fiber-reinforced molded product 10 is preferably a resin ratio R represented by the following formula (B1). (weight ratio) is 50 to 80%, and particularly preferably 55 to 70%. By setting such a resin ratio, even if the fiber-reinforced molded product 10 is made thinner, the lightweight property and rigidity can be further improved.

R=(Wb-Wa)/Wb×100 (B1)

(Wa: total weight of member for core material, fiber woven fabric, and porous sheet, Wb: total weight of member for core material, fiber woven fabric, and porous sheet after impregnating thermosetting resin, R: resin ratio)

In addition, the weight after impregnating the thermosetting resin in the formula (B1) of the resin ratio is a weight which is dried after being impregnated to remove the solvent, and is used after the thermosetting resin is dissolved in a solvent.

The surface material 25 is a thermosetting resin which is at least one of a thermosetting resin for a reinforcing material and a thermosetting resin for a core material (hereinafter, the thermosetting resin for thermosetting resin and the core material are not particularly distinguished from each other) In the case of a resin, abbreviated as a thermosetting resin) is impregnated in a porous sheet and hardened. Further, in the compression heating step in the case of producing the fiber-reinforced molded article 10, the thermosetting resin impregnated in the porous sheet is further exuded from the surface of the porous sheet and hardened on the surface to be surface-hardened. The surface of the material 25 forms a smooth resin layer. Thereby, the surface roughness of the surface material 25 is 30 μm or less, and more preferably 24 μm or less. When the surface roughness is more than 30 μm, when the surface of the surface material 25 is applied, the unevenness is conspicuous, and it is difficult to obtain a good coated surface. Further, when the surface of the surface material 25 is polished after the thermosetting resin is cured, the surface roughness can be further reduced.

The surface material is formed by infiltrating a thermosetting resin into a porous sheet having continuous cells and having a number of micropores of 8 to 80/25 mm by capillary action. Therefore, the thermosetting resin is easily oozing out to the surface through the continuous bubbles, so that the surface is exuded to the surface of the surface material to form a smooth surface. Thereby, the surface roughness of the surface material can be made 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and a good appearance can be obtained.

Further, since most of the smooth surface is a thermosetting resin which is exuded from the porous sheet, it is integrated with the fiber-reinforced molded body, and is not peeled off together with the coating film. Moreover, since the thermosetting resin and the coating film have high adhesiveness, it exhibits good coating film adhesion.

In order to improve the impregnation of the thermosetting resin, a uniform resin layer is formed on the surface, and the porous sheet is formed of a porous material having continuous cells. The material of the porous sheet is not particularly limited, and it is preferably not melted in addition to the porosity, and is not melted by the heat in the compression heating step, and has heat resistance to the extent that the pores are not to be filled. Further, the form of the porous sheet is not particularly limited, and may be appropriately selected from woven fabrics, non-woven fabrics, papers, foams, and the like.

Further, when a resin foam having continuous cells is used as the porous sheet, the skeleton shape of the resin is stable and voids are maintained as compared with the porous body including the fibers, so that the gas permeability and the fluidity of the matrix resin become It is good that the thermosetting resin easily bleeds out to the surface of the porous sheet, and it becomes easy to obtain a smooth surface. In the resin foam having continuous cells, the porous sheet containing the urethane resin foam is easy to handle, is excellent in light weight, and can effectively alleviate the fiber fabric of the fiber reinforcing material 21 caused by shrinkage. It is preferable to have a step difference such as a gap portion of the woven eye.

Further, in the case where the porous sheet is composed of a urethane resin foam, it is particularly preferable to remove the microporous membrane by a known membrane removal treatment such as a dissolution treatment or an explosion treatment. The urethane resin foam from which the microporous membrane is removed has a continuous cell structure having a good liquid permeability. Therefore, in the compression and heating step, the thermosetting resin is easily impregnated into the porous sheet, and is easily oozing out. To the surface of the porous sheet. Therefore, the integration of the core material 11 with the fiber reinforcing material 21 and the surface material 25 can be made more reliable by the hardening of the thermosetting resin, and the thermosetting resin which is exuded from the surface of the porous sheet Hardens and becomes easy to obtain a smooth surface.

Further, since the urethane resin foam in which the microporous film is not removed remains in the microporous film, when it is used for a porous sheet, the impregnation and bleed out of the thermosetting resin are poor, and as a result, the surface is smooth. Sex and coating adhesion (difficulty in peeling off the film) is reduced.

The porous sheet is preferably one having a micropore number of 8 to 80/25 mm (JIS K6400-1). When the number of micropores is less than 8/25 mm, the void (pore) becomes too large when processed into a thin sheet, and there is an amount which is difficult to maintain the unevenness of the buried fiber fabric. The tendency of a thermosetting resin. On the other hand, when the number of micropores is more than 80/25 mm, the amount of voids is small, and the impregnation property of the thermosetting resin is lowered, so that it is difficult to make the thermosetting resin sufficiently from the surface of the porous sheet. Exudation.

The thickness of the porous sheet to be used varies depending on the material, and is 0.4 mm to 3.0 mm, more preferably 0.6 mm to 3.0 mm, in the uncompressed state (before the production of the fiber-reinforced molded article). When the thickness in the uncompressed state is less than 0.4 mm, it becomes difficult to form a uniform resin layer on the surface of the surface material 25 in the compression heating step in the production of the fiber-reinforced molded product 10, and the surface of the fiber-reinforced molded body 10 is Smoothness is reduced. On the other hand, if the thickness of the porous sheet under the uncompressed state (before the production of the fiber-reinforced formed body) is more than 3.0 mm, the bending elastic modulus of the fiber-reinforced molded product 10 is lowered, and the fiber-reinforced forming is performed. At the time of the body 10, unevenness of bleeding of the thermosetting resin from the porous sheet is likely to occur, and the smoothness of the surface of the surface material 25 is lowered.

The integration of the core material 11 with the fiber reinforcing material 21 and the surface material 25 can be carried out by impregnating or adhering the thermosetting resin to at least one of the core material and the fiber fabric on at least one side of the core material. The fiber woven fabric and the porous sheet are sequentially laminated, and the thermosetting resin is cured in a compressed state.

When the thermosetting resin is applied or impregnated into both the core material and the fiber fabric, the thermosetting resin for the core material and the thermosetting resin for the fiber reinforcing material may be of the same type or different types, in order to The core material 11 and the fiber reinforcing material 21 have good adhesion, and are preferably of the same type.

On the surface of the surface material 25 in the fiber-reinforced molded product 10, a coating film is formed by coating by a specific method depending on the application. Examples of the coating material include urethane-based, acrylic-based, polyester-based, and vinyl acetate-based, and examples of the coating method include spray coating, coater coating, and dip coating. . The coating amount can be appropriately determined, and for example, a coating film 27 having a film thickness of 5 to 40 μm can be formed. Fig. 2 shows a fiber-reinforced molded body in which a coating film 27 is applied by coating on the surface of the surface material 25. The surface roughness of the coating film 27 is 25 μm or less, more preferably less than 20 μm.

Further, the fiber reinforcing material 21 is preferably laminated on both surfaces of the core material 11. When the fiber reinforcing material 21 is laminated on both surfaces, the tensile strength of both sides of the fiber-reinforced molded product is improved, and the bending strength of the entire fiber-reinforced molded product is improved. At this time, in consideration of only the tensile strength, the fiber reinforcing material 21 is preferably disposed on the outermost layer of the fiber-reinforced molded product.

However, when the fiber-reinforced molded product is produced, the thermosetting resin does not ooze back into the surface of the fiber woven fabric of the fiber-reinforced material 21, and the surface may be unevenly formed to cause deterioration of the appearance of the fiber-reinforced molded product. Therefore, the surface material (porous sheet) 25 which is thinner than the core material 11 having good compatibility with the thermosetting resin is disposed on the fiber fabric, and a void which causes the thermosetting resin to bleed back into the surface of the fiber fabric is formed. The porous sheet absorbs the thermosetting resin which penetrates into the fiber fabric by capillary action, and hardens the thin thermosetting resin layer which oozes out to the surface of the porous sheet, thereby forming smoothness on the fiber-reinforced molded body. The surface. In this way, a fiber-reinforced molded product in which bending strength and appearance are simultaneously achieved can be obtained.

Next, a method for producing a fiber-reinforced molded product according to the first to (1) to the first (4) embodiments of the present invention will be described.

(1-1-1) Embodiment)

First, a method for producing a fiber-reinforced molded product according to the first (1)th embodiment of the present invention will be described with reference to Fig. 3 . The method for producing the fiber-reinforced molded product 10 includes an impregnation step, a lamination step, and a compression heating step as described below. In the method for producing a fiber-reinforced molded article according to the first embodiment of the present invention, the thermosetting resin 21B for reinforcing material is impregnated into the fiber fabric 21A only in the impregnation step.

In the impregnation step shown in (3-1) of Fig. 3, the fiber fabric 21A is impregnated or adhered to the thermosetting resin 21B for reinforcing material to form the impregnated fiber fabric 21C. In addition, the term "impregnation" as used herein means that the fiber fabric 21A is immersed in a groove in which the liquid thermosetting resin 21B for reinforcing material is contained, and is also sprayed or a roll coater. The reinforcing material is held in the fiber fabric 21A by adhesion or coating, or by other appropriate methods.

The fiber fabric 21A and the thermosetting resin 21B for reinforcing material are used as described above. The thermosetting resin 21B for reinforcing material is an unhardened liquid. In addition, in order to facilitate the impregnation, the thermosetting resin 21B for reinforcing material is preferably dissolved in a solvent, and the impregnated fiber is impregnated at a temperature at which the reinforcing material is hardened by the thermosetting resin 21B after impregnation. The fabric 21C is dried, whereby the solvent is removed from the impregnated fiber fabric 21C.

In the impregnation step, the resin ratio R in the following formula (B1) is preferably 50 to 80%, and particularly 55 to 70%, and the thermosetting resin 21B for reinforcing material is impregnated into the fiber fabric 21A. in.

R=(Wb-Wa)/Wb×100 (B1)

(Wa: total weight of member for core material, fiber woven fabric, and porous sheet, Wb: total weight of member for core material, fiber woven fabric, and porous sheet after impregnating thermosetting resin, R: resin ratio)

In the impregnation step, the total weight of the thermosetting resin 21B impregnated in the fiber fabric 21C is equal to the value of Wb-Wa in the formula (B1) of the resin ratio R. In addition, the weight after impregnating the thermosetting resin in the formula (B1) of the resin ratio R is a weight obtained by drying the solvent after drying and removing the solvent after the thermosetting resin is dissolved in a solvent.

Next, in the laminating step shown in (3-2) of FIG. 3, the impregnated fiber fabric 21C is placed on both surfaces of the core member 11A, and the impregnated fiber on one side of the core member 11A is further disposed. The porous sheet 25A is placed on the surface of the woven fabric 21C to form a laminated body 10A. The materials used for the core member 11A and the porous sheet 25A are as described above. Further, the porous sheet 25A used herein is a sheet having continuous cells having a number of micropores of 8 to 80/25 mm and a thickness of 0.4 to 3.0 mm.

The laminating operation can sequentially overlap the impregnated fiber fabric 21C, the core member 11A, and the impregnated fiber fabric on the upper surface of the mold (the lower mold for extrusion molding) 31 used in the subsequent compression heating step. 21C and the porous sheet 25A were carried out. Further, the fiber fabric 21C to be impregnated, the core member 11A and the porous sheet 25A preferably have the same planar size, but in the case of different conditions, the trimming may be performed after the compression heating step described below.

Next, in the compression heating step shown in (3-3) of FIG. 3, heating is performed while compressing the laminated body 10A by the lower mold 31 and the upper mold 33. The degree of compression is preferably such that the compression ratio C defined by the following formula (A1) is in the range of 200 to 5000%, and more preferably in the range of 1000 to 2600%. By setting the range of the above-described compression ratio C, it is possible to improve the thickness and rigidity of the fiber-reinforced molded product 110.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

Further, the compression is preferably performed so that the thickness of the laminated body 10A is 0.3 to 2.0 mm. In the compression heating step, a spacer is provided between the lower mold 31 and the upper mold 33 at an appropriate position so that the distance between the lower mold 31 and the upper mold 33 becomes a specific interval (a specific compression thickness of the laminated body 10A). Further, the heating method of the laminated body 10A is not particularly limited, but it is simpler to provide a heating means such as a heater to the lower mold 31 and the upper mold 33, and to heat the upper mold 31 via the lower mold 31. The heating temperature is equal to or higher than the curing reaction temperature of the thermosetting resin 21B for the reinforcing material to be impregnated.

When the laminated body 10A is compressed at the compression heating step, the fiber fabric 21C impregnated from the laminated body 10A is extruded from the thermosetting resin 21B, and impregnated or adhered to the fiber fabric 21C which has been impregnated. The core member 11A is also impregnated into the porous sheet 25A. The thermosetting resin 21B for the reinforcing material impregnated in the porous sheet 25A is further exuded to the surface of the porous sheet 25A and hardened to form a resin layer having a smooth surface.

In this manner, the thermosetting resin 21B is infiltrated into the porous sheet 25A containing the continuous cells having a number of micropores of 8 to 80/25 mm by capillary action, and is hardened to form the surface material 25, so that the thermosetting resin is easily formed. 21B oozes out to the surface through continuous bubbles. The smoothing surface is formed by the thermosetting resin 21B which is oozing to the surface of the surface material 25. Thereby, the surface roughness of the surface material 25 can be 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and a good appearance can be obtained. In addition, since the smooth surface is formed of the thermosetting resin 21B which oozes out from the porous sheet 25A, the smooth surface is integrated with the fiber-reinforced molded body, and there is no case where the coating film 27 is peeled off together. Moreover, since the adhesion between the thermosetting resin 21B and the coating film 27 is high, it exhibits good coating film adhesion.

At the time of the compression step, the thermosetting resin 21B for the reinforcing material exceeding the space capacity of the core material member 11A, the fiber fabric 21A, and the porous sheet 25A after the compression is extruded to the outside of the mold. In addition, in the case of the fine voids in the thermosetting resin 21B for the reinforcing material or the minute voids which are inadvertently formed, the thermosetting resin 21 for the reinforcing material is densely filled so that the voids are not actually present in the laminated body 10A. . Therefore, the rigidity of the laminated body 10A can be improved.

The thermosetting resin 21B for the reinforcing material impregnated in the laminated body 10A is cured by heating, and is cured in a state where the laminated body 10A is compressed. In the case where the core material member 11A has continuous cells, the reinforcing material impregnated in the impregnated fiber fabric 21C is oozing out and impregnated into the core member 11A, and the laminated body 10A is compressed. In this state, the reinforcing material is cured by the thermosetting resin 21B. In the case where the porous sheet 25A contains the urethane resin foam, the reinforcing material is cured with the thermosetting resin in a state where the porous sheet 25A is also compressed. Therefore, the core member 11A, the fiber fabric 21A, and the porous sheet 25A are integrated by the hardening of the thermosetting resin 21B for the reinforcing material.

Thereby, the core material 11 is formed from the core member 11A, the fiber reinforcement 21 is formed from the impregnated fiber fabric 21C, the surface material 25 is formed from the porous sheet 25A, and the core is made of a thermosetting resin by the reinforcing material. The material 11 is integrated with the fiber reinforcing material 21 and the surface material 25 to form the fiber-reinforced molded product 10.

Thereafter, the heat compression is released to obtain the fiber-reinforced molded product 10. In the fiber-reinforced molded product 10 obtained in this manner, the surface of the surface material 25 is cured by the hardening resin 21B for reinforcing the reinforcing material 21B which is oozing out to the surface of the porous sheet 25A.

Moreover, when the resin ratio R and the compression ratio C are set to the above specific range, the fiber-reinforced molded product having high rigidity can be easily provided. At this time, in order to achieve a high compression ratio, it is preferable to use a resin foam for the core member 11A.

In addition, when the core material member having the continuous air bubbles is used as the core material member 11A, the thermosetting resin 21B is uniformly dispersed in the continuous cell structure in which the thermosetting resin 21B is adhered to the core member 11A. In the core member 11A. When the thermosetting resin 21B is cured in this state, the thermosetting resin 21B is densely filled in the core member 11A, and the fiber having the bending strength and the adhesion strength between the core material and the fiber reinforcing material 21 can be obtained. Strengthen the molded body.

Further, if the compression ratio C and the resin ratio R defined by the above formulas (A1) and (B1) are set to be in the range of 200 to 5000% and 50 to 80%, respectively, the fiber-reinforced molded article can be reduced. The size of the tiny gap. In addition, when the resin foam is used as the core member 11A, the resin foam is used as the core material member 11A, and the foamed resin skeleton of the resin foam dispersed in the thermosetting resin 21B is used. The uniformity is improved, and the strength of the fiber-reinforced molded body is made uniform. That is, the weakened portion of the fiber-reinforced molded body disappears. In this case, when the resin foam is cured in a compressed state to produce a fiber-reinforced molded product, the distance between the skeletons of the resin foams is smaller than the distance between the skeletons before compression, and the skeleton of the resin foam is also fibers. The reinforced molded body has a flat shape in the thickness direction.

(1-1-(2) embodiment)

Next, a fiber-reinforced molded product according to a first to (2)th embodiment of the present invention and a method for producing the same will be described with reference to Fig. 4 .

In the above-described first (1) embodiment, the reinforcing material thermosetting resin 21B is impregnated into the fiber fabric 21A in the impregnation step to form the impregnated fiber fabric 21C. On the other hand, in the first embodiment, in the impregnation step, the core material thermosetting resin 11B is impregnated into the core member 11A to form the impregnated core member 11C.

When the core material member 11A is a resin foam having continuous cells, the core material thermosetting resin 11B is impregnated into the core member 11A. On the other hand, when a member which is difficult to impregnate, for example, a member which is not porous, is used as the core member 11A, the core material thermosetting resin 11B may be adhered to the surface of the core member 11A. In the following description, the case where the core material thermosetting resin 11B is adhered to the surface of the core material member 11A is also included in the case where the core material thermosetting resin 11B is impregnated into the core material. In the concept in component 11A.

The core member 11A and the core thermosetting resin 11B are as described in the fiber-reinforced molded article 10. The thermosetting resin 11B for core materials used in the impregnation step contains an unhardened liquid. In addition, in order to facilitate the impregnation, the core material thermosetting resin 11B is preferably dissolved in a solvent, and after impregnation, the impregnated one is dried at a temperature at which the core material thermosetting resin 11B is hardened. The core material member 11C removes the solvent from the core material member 11C which has been impregnated.

The impregnation method can be suitably carried out by a method of immersing the core member 11A in a bath containing the liquid core material thermosetting resin 11B, a method of applying by spraying, a coating method by a roll coater, and the like. The method is carried out. The core material thermosetting resin 11B is impregnated or adhered to the core member 11A so that the resin ratio R is 50 to 80%, and particularly 55 to 70%. In the impregnation step, the weight of the core material thermosetting resin 11B impregnated into the core member 11A is equal to the Wb-Wa in the formula (B1) of the resin ratio. Further, the weight after impregnation in the formula of the resin ratio is a weight obtained by drying the solvent after drying and removing the solvent when the thermosetting resin is dissolved in a solvent.

In the laminating step shown in (4-2) of FIG. 4, the fiber fabric 21A is placed on both surfaces of the impregnated core member 11C, and further on the side of one side of the impregnated core member 11C. The porous sheet 25A is placed on the surface of the fiber woven fabric 21A to obtain a laminated body 10B. The fiber fabric 21A and the porous sheet 25A are as described in the fiber-reinforced molded article 10.

Further, the laminating operation may sequentially overlap the fiber fabric 21A, the impregnated core member 11C, the fiber fabric 21A, and the porous sheet 25A on the upper surface of the mold 31 used in the subsequent compression heating step. get on. Further, the core material member 11C to be impregnated, the fiber fabric 21A and the porous sheet 25A preferably have the same planar size, but in the case of different conditions, the trimming may be performed after the compression heating step described below.

In the compression heating step shown in (4-3) of FIG. 4, the laminate 10B is compressed by the lower mold 31 and the upper mold 33 while being heated. The degree of compression is preferably in the range of 200 to 5000%, particularly preferably 1000 to 2600%, as defined by the following formula (A1). By setting the range of the above-described compression ratio C, it is possible to improve the thickness and rigidity of the fiber-reinforced molded product 110.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

Further, the compression is preferably performed so that the thickness of the laminated body 10B is 0.3 to 2.0 mm. At the time of the compression heating step, a spacer is provided between the lower mold 31 and the upper mold 33 at an appropriate position so that the distance between the lower mold 31 and the upper mold 33 becomes a specific interval (a specific compression thickness of the laminate). Further, the heating method of the laminated body is not particularly limited, but it is simpler to provide a heating means such as a heater to the lower mold 31 and the upper mold 33, and the lower mold 31 and the upper mold 33 are used. The heating temperature is equal to or higher than the curing reaction temperature of the thermosetting resin 11B for core material to be impregnated.

When the laminated body 10B is compressed in the compression heating step, when the core member 11A contains a resin foam having continuous cells, the core material is extruded from the core member 11C with the thermosetting resin 11B. Further, it is impregnated into the fiber fabric 21A which is in contact with the core member 11C which has been impregnated, and further impregnated into the porous sheet 25A. On the other hand, when the core member 11A contains a member which is difficult to impregnate, for example, a member which is not porous, the surface of the core member 11C to which the core material thermosetting resin 11B is adhered is compressed. It is impregnated into the fiber fabric 21A and further impregnated into the porous sheet 25A.

The core material thermosetting resin 11B impregnated in the porous sheet 25A is oozing out to the surface of the porous sheet 25A by compression and hardened to form a smooth surface containing the resin layer.

In this way, the thermosetting resin 11B is infiltrated into the porous sheet 25A having the number of micropores of 8 to 80/25 mm and is hardened by the capillary phenomenon to form the surface material 25, so that the thermosetting resin is easily formed. 11B oozes out to the surface through continuous bubbles. The surface of the thermosetting resin 11B exuded to the surface material 25 forms a smooth surface. Thereby, the surface roughness of the surface material 25 can be made 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and an excellent appearance can be obtained. In addition, since the smooth surface is formed of the thermosetting resin 11B which has been oozing from the porous sheet 25A, the smooth surface is integrated with the fiber-reinforced molded body, and there is no possibility of being peeled off together with the coating film 27. Moreover, since the adhesion between the thermosetting resin 11B and the coating film 27 is high, it exhibits good coating film adhesion.

At the time of compression, the core material thermosetting resin 11B which is excessive in excess of the space volume of the core material member 11A, the fiber woven fabric 21A, and the porous sheet 25A after being compressed is extruded to the outside of the mold. In addition, the fine voids in the core material thermosetting resin 11B or the minute voids which are inadvertently formed are excluded, and the core material thermosetting resin 11B is densely filled in the laminate so that the voids are not actually present. In body 10B. Thereby, the rigidity of the fiber-reinforced molded product 10 can be improved.

The thermosetting resin 11B for core material impregnated in the whole laminated body 10B is hardened by heating, and hardens in a compressed state. In the case where the core material member 11A contains a resin foam having continuous cells, the core material thermosetting resin 11B is cured in a compressed state. In the case where the porous sheet 25A contains the urethane resin foam, the core material thermosetting resin 11B is cured in a state where the porous sheet 25A is also compressed.

The core material 11 is formed from the impregnated core member 11C by the above compression heating step, and the fiber reinforcement 21 is formed from the fiber fabric 21A, and the surface material 25 is formed from the porous sheet 25A so that the core material 11 and the fiber The reinforcing material 21 and the surface material 25 are integrated to form the fiber-reinforced molded product 10. Thereafter, the heating and compression are released to obtain the fiber-reinforced molded product 10. On the surface of the surface material 25 of the fiber-reinforced molded product 10 thus obtained, the resin material having a smooth surface is formed by hardening of the core material thermosetting resin 11B which has been oozing to the surface of the porous sheet 25A.

Moreover, when the resin ratio R and the compression ratio C are set to the above specific range, the fiber-reinforced molded product having high rigidity can be easily provided. At this time, in order to achieve a high compression ratio, it is preferable to use a resin foam for the core member 11A.

In addition, when the core material member having the continuous air bubbles is used as the core material member 11A, the thermosetting resin 11B can be uniformly dispersed in the continuous cell structure in which the thermosetting resin 11B is adhered to the core member 11A. In the core member 11A. When the thermosetting resin 11B is cured in this state, the thermosetting resin 11B can be densely filled in the core member 11A, and the fiber having the bending strength and the adhesion strength of the core material and the fiber reinforcing material 21 can be obtained. Strengthen the molded body.

In addition, by setting the compression ratio C and the resin ratio R defined by the above formulas (A1) and (B1) to 200 to 5000% and 50 to 80%, respectively, it is possible to reduce the minute amount contained in the fiber-reinforced molded product. The size of the gap. In addition, when the resin foam is used as the core member 11A, the resin foam is used as the core material member 11A, and the foamed resin skeleton of the resin foam dispersed in the thermosetting resin 11B is used. The uniformity is improved to uniformize the strength of the fiber-reinforced molded body. That is, the weakened portion of the fiber-reinforced molded body disappears. In this case, when the resin foam is cured in a compressed state to produce a fiber-reinforced molded product, the distance between the skeletons of the resin foams is smaller than the distance between the skeletons before compression, and the skeleton of the resin foam is also fibers. The reinforced molded body has a flat shape in the thickness direction.

(1-1-(3) embodiment)

Next, a method for producing a fiber-reinforced molded product according to the first (3)th embodiment of the present invention will be described with reference to Fig. 5 . In the first to (1) and (1)th embodiments, the thermosetting resins 11B and 21B are impregnated into the core member 11A or the fiber fabric 21A in the impregnation step. However, in the impregnation step of the present embodiment, as shown in (5-1) of FIG. 5, the core material thermosetting resin 11B is impregnated into the core member 11A to obtain the impregnated core material. Further, the member 11C is further impregnated with the thermosetting resin 21B for the reinforcing material in the fiber fabric 21A to form the impregnated fiber fabric 21C.

The core material member 11A, the core material thermosetting resin 11B, the fiber fabric 21A, and the reinforcing material thermosetting resin 21B are as described in the fiber reinforced molded product 10. The thermosetting resins 11B and 21B used in the impregnation are in an unhardened liquid state.

In addition, in order to facilitate the impregnation, the thermosetting resins 11B and 21B are preferably dissolved in a solvent, and after impregnation, the impregnated core is heated at a temperature that does not cause the thermosetting resins 11B and 21B to harden. The material member 11C and the impregnated fiber fabric 21C are dried, and the solvent is removed from the impregnated core material member 11C and the impregnated fiber fabric 21C. The impregnation method is, for example, a method of immersing the core member 11A or the fiber woven fabric 21A in a tank containing the liquid thermosetting resins 11B and 21B, a method of applying by spraying, or coating by a roll coater. Suitable methods such as the method of cloth.

In the impregnation step, the impregnation of the core material thermosetting resin 11B into the core member 11A and the impregnation of the reinforcing material thermosetting resin 21B into the fiber fabric 21A are preferably 50 to 80% by resin. Especially, it is done in 55~70% way. In the impregnation step, the total weight of the core material thermosetting resin 11B impregnated in the core member 11A and the weight of the thermosetting resin 21B impregnated in the fiber fabric 21A are the formula of the resin ratio (B1). The value of Wb-Wa in the middle). Further, the weight after impregnation in the formula of the resin ratio is a weight obtained by drying the solvent after drying and removing the solvent when the thermosetting resin is dissolved in a solvent.

In the laminating step shown in (5-2) of Fig. 5, the impregnated fiber fabric 21C is placed on both sides of the impregnated core member 11C, and further on one side of the impregnated core member 11C. The porous sheet 25A is placed on the surface of the impregnated fiber fabric 21C to form a laminated body 10C. The porous sheet 25A is as described in the fiber-reinforced molded product 10.

Further, the laminating operation may sequentially overlap the impregnated fiber fabric 21C, the impregnated core member 11C, the impregnated fiber fabric 21C, and the porous surface of the mold 31 in the subsequent compression heating step. The sheet 25A was carried out. Further, the impregnated core material member 11C and the impregnated fiber fabric 21C and the porous sheet 25A preferably have the same planar size, but in different cases, as long as the following compression heating step is performed, Just trim it.

Next, in the compression heating step shown in (5-3) of Fig. 5, heating is performed while compressing the laminated body 10C by the lower mold 31 and the upper mold 33. The degree of compression is preferably in the range of 200 to 5000%, particularly preferably 1000 to 2600%, as defined by the following formula (A1). By setting the range of the above-described compression ratio, it is possible to increase the thickness and rigidity of the fiber-reinforced molded product 110.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

Further, the compression is preferably performed so that the thickness of the laminated body 10C is 0.3 to 2.0 mm. In the compression heating step, a spacer is provided between the lower mold 31 and the upper mold 33 at an appropriate position so that the distance between the lower mold 31 and the upper mold 33 becomes a specific interval (a specific compression thickness of the laminated body). .

Further, the heating method is not particularly limited, but it is simpler to provide a heating means such as a heater to the lower mold 31 and the upper mold 33, and the lower mold 31 and the upper mold 33 are used. The heating temperature is equal to or higher than the curing reaction temperature of the thermosetting resin to be impregnated.

By the compression in the compression heating step, the thermosetting resin 21B for the reinforcing material of the impregnated fiber fabric 21C and the core material thermosetting resin 11B of the impregnated core material member 11C can be surely brought into contact with each other, and The thermosetting resin 21B for reinforcing material is surely impregnated into the porous sheet 25A. Moreover, the thermosetting resin 21B for reinforcing material impregnated in the porous sheet 25A oozes out to the surface of the porous sheet 25A to form a resin layer having a smooth surface.

In this manner, the thermosetting resin 11B, 21B is infiltrated into the porous sheet 25A having the number of micropores of 8 to 80/25 mm and is hardened by the capillary phenomenon to form the surface material 25, so that it is easy to be thermally hardened. The resin 11B, 21B oozes out to the surface by continuous bubbles. The smoothing surface is formed by the thermosetting resins 11B, 21B which are oozing to the surface of the surface material 25. Thereby, the surface roughness of the surface material 25 can be made 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and an excellent appearance can be obtained. In addition, since the smooth surface is formed of the thermosetting resins 11B and 21B which are oozing from the porous sheet 25A, the smooth surface and the fiber-reinforced molded body are integrated, and there is no possibility of being peeled off together with the coating film 27. Moreover, since the thermosetting resins 11B and 21B have high adhesion to the coating film 27, they exhibit good coating film adhesion.

In addition, the thermosetting resins 11B and 21B which are excessive in excess of the space volume of the core member 11A, the fiber woven fabric 21A, and the porous sheet 25A after being compressed are extruded to the outside of the mold. Except for the minute voids which are present in the thermosetting resins 11B and 21B or the minute voids which are inadvertently formed, the thermosetting resins 11B and 21B are densely filled in the fiber-reinforced molded body 10 so that there is substantially no void. . Thereby, the rigidity of the fiber-reinforced molded body is improved.

Then, by the heating in the compression heating step, the thermosetting resins 11B and 21B start to harden and react, and the layered body 10C is cured in a compressed state. In the case where the core member 11A includes a resin foam having continuous cells, the core material thermosetting resin 11B is cured in a compressed state. In the case where the porous sheet 25A contains the urethane resin foam, the thermosetting resin 21B for the reinforcing material is cured in a state where the porous sheet 25A is also compressed.

Thereby, the core material 11 is formed from the core member 11C which has been impregnated, the fiber reinforcing material 21 is formed from the impregnated fiber fabric 21C, and the surface material 25 is formed from the porous sheet 25A to reinforce the core material 11 and the fiber. The material 21 and the surface material 25 are integrated to form the fiber-reinforced molded body 10. Thereafter, the heating and compression are released to obtain the fiber-reinforced molded product 10. On the surface of the surface material 25 of the fiber-reinforced molded product 10 thus obtained, a resin layer having a smooth surface is formed by hardening of a thermosetting resin which bleeds out to the surface of the porous sheet 25A.

Moreover, when the resin ratio R and the compression ratio C are set to the above specific range, the fiber-reinforced molded product having high rigidity can be easily provided. At this time, in order to achieve a high compression ratio, it is preferable to use a resin foam for the core member 11A.

When the core material member having the continuous air bubbles is used as the core material member 11A, the thermosetting resin 11B, 21B can be made by adhering the thermosetting resin 11B, 21B to the continuous cell structure of the core material member 11A. It is uniformly dispersed in the core member 11A. By curing the thermosetting resins 11B and 21B in this state, the thermosetting resins 11B and 21B can be densely filled in the core member 11A, and the bending strength and the adhesion strength between the core material and the fiber reinforcing material can be obtained. Improved fiber reinforced molded body.

In addition, by setting the compression ratio C and the resin ratio R defined by the above formulas (A1) and (B1) to 200 to 5000% and 50 to 80%, respectively, it is possible to reduce the minute amount contained in the fiber-reinforced molded product. The size of the gap. In addition, when the resin foam is used as the core member 11A, the foamed resin of the resin foam dispersed in the thermosetting resins 11B and 21B is used. The uniformity of the skeleton is increased to uniformize the strength of the fiber-reinforced molded body. That is, the weakened portion of the fiber-reinforced molded body disappears. In this case, when the resin foam is cured in a compressed state to produce a fiber-reinforced molded product, the distance between the skeletons of the resin foams is smaller than the distance between the skeletons before compression, and the skeleton of the resin foam is also fibers. The reinforced molded body has a flat shape in the thickness direction.

(1-th-4th embodiment)

Next, a fiber-reinforced molded product according to a first to (four)th embodiment of the present invention and a method for producing the same will be described with reference to Fig. 6 .

First, in the impregnation step shown in (6-1) of FIG. 6, the reinforcing material thermosetting resin 21B is impregnated into the two fiber fabrics 21A to form two impregnated fiber fabrics 21C. Next, a porous sheet 25A was laminated on the two sheets of the impregnated fiber fabric 21C. In addition, in order to remove the solvent contained in the thermosetting resin 21B for the reinforcing material, the prepreg 20 in a semi-hardened state is produced by drying at a temperature at which the reinforcing material is not cured by the thermosetting resin 21B. The semi-hardened prepreg 20-fiber fabric 21A and the porous sheet 25A are adhered to a certain degree of strength, and the handling is relatively easy. Moreover, the thermosetting resin 21B can be applied to the fiber fabric 21A by applying a spray or a coating roll in a state where the fiber fabric 21A is laminated on the porous sheet 25A, and the above-mentioned impregnated carbon fiber fabric can be applied. The prepreg 20 is produced while 21C is being formed. The prepreg 20 can also be formed by forming a long strip of fiber fabric and a porous sheet, and cutting a long prepreg.

In addition to the fiber fabric 21A, the core material thermosetting resin 11B may be impregnated into the core material member 11A to form the impregnated core material member 11C. In this case, when the thermosetting resin 21B for reinforcing material and the thermosetting resin 11B for core material are made of the same material, the adhesion between the core material 11 and the fiber reinforcing material 21 is improved, which is preferable.

In the impregnation step, impregnation of the core material thermosetting resin 11B with the core material member 11A and/or impregnation of the thermosetting resin 21B with the fiber fabric 21A is preferably a resin ratio specified by the above formula (B1). R is 50 to 80%, especially 55 to 70%.

In addition, the weight of the core material thermosetting resin 11B impregnated in the core member 11A and/or the weight of the thermosetting resin 21B impregnated into the fiber fabric 21A and the resin ratio of the Wb in the above formula (B1) (=the total weight of the core member (thermosetting resin foam), the fiber fabric (carbon fiber fabric), and the porous sheet after impregnating the thermosetting resin)-Wa (=the core of the thermosetting resin before impregnation) The material member (thermosetting resin foam), the fiber fabric (carbon fiber fabric), and the total weight of the porous sheet are equal in value. In addition, the weight after impregnation in the formula (B1) of the resin ratio is a case where the thermosetting resin is dissolved in a solvent and used, and the weight after drying is removed to remove the solvent.

Further, the material used for the core member 11A, the fiber woven fabric 21A, the porous sheet 25A, the core material thermosetting resin 11B, and the reinforcing material thermosetting resin 21B can be the same as those of the above embodiment.

Next, in the laminating step shown in (6-2) of FIG. 6, two prepregs 20 are laminated on both surfaces of the core member 11A to form a laminated body 10D. Here, each of the prepregs 20 is laminated on the core member 11A so that the impregnated fiber web 21C comes into contact with the core member 11A.

Further, in (6-2) of Fig. 6, the two prepregs 20 and the core member 11A are separated from each other for the sake of explanation, but actually, both are laminated without being separated. In the laminating step, if the prepreg 20 and the core member 11A are laminated in the molds 31 and 33 used in the compression heating step described below, the step of disposing the laminated body 10D in the mold can be omitted. Therefore, it is preferred.

Next, in the compression heating step shown in (6-3) of Fig. 6, the laminated body 10D is subjected to compression heating. Thereby, a fiber-reinforced molded body in which the surface material 25, the fiber reinforcing material 21, the core material 11, the fiber reinforcing material 21, and the surface material 25 are laminated in this order from bottom to top is obtained.

This compression heating step can be carried out, for example, by disposing the laminated body 10D between the lower mold 31 and the upper mold 33 as shown in the drawing so that the two are close to each other until the distance between the lower mold 31 and the upper mold 33 becomes specific. Further, the laminated body 10D can be heated by the lower mold 31 and the upper mold 33. The compression is preferably such that the compression ratio obtained by the formula (A1) is 200 to 5000%, and particularly preferably 1000 to 2600%, and further preferably, the compression system has a thickness of the laminate 10D of 0.3 to 2.0 mm. Way to proceed.

Further, by adjusting the distance between the lower mold 31 and the upper mold 33, the compression ratio can be freely set. The distance between the lower mold 31 and the upper mold 33 can be easily adjusted by inserting the adjustment spacer between the lower mold 31 and the upper mold 33.

In the compression heating step, the thermosetting resin 21B for reinforcing material is exuded from the impregnated fiber fabric 21C to the core member 11A and the porous sheet 25 by compressing the laminated body 10D. By heating the laminated body 10D in such a compressed state, the core member 11A, the fiber woven fabric 21A, and the porous sheet 25 can be integrated by curing of the thermosetting resin 21B for reinforcing members.

In this manner, the thermosetting resin 21B is infiltrated into the porous sheet 25A having continuous cells having a number of micropores of 8 to 80/25 mm by capillary action and hardened to form the surface material 25, so that the thermosetting resin is easily formed. 11B, 21B ooze out to the surface through continuous bubbles. The smoothing surface is formed by the thermosetting resins 11B, 21B which are oozing to the surface of the surface material 25. Thereby, the surface roughness of the surface material 25 can be made 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and an excellent appearance can be obtained. In addition, since the smooth surface is formed of the thermosetting resins 11B and 21B which are oozing from the porous sheet 25A, the smooth surface and the fiber-reinforced molded body are integrated, and there is no possibility of being peeled off together with the coating film 27. Moreover, since the thermosetting resins 11B and 21B have high adhesion to the coating film 27, they exhibit good coating film adhesion.

Moreover, when the resin ratio R and the compression ratio C are set to the above specific range, the fiber-reinforced molded product having high rigidity can be easily provided. At this time, in order to achieve a high compression ratio, it is preferable to use a resin foam for the core member 11A.

When the core material member having the continuous air bubbles is used as the core material member 11A, the thermosetting resin 11B, 21B can be made by adhering the thermosetting resin 11B, 21B to the continuous cell structure of the core material member 11A. It is uniformly dispersed in the core member 11A. When the thermosetting resins 11B and 21B are cured in this state, the thermosetting resins 11B and 21B can be densely filled in the core member 11A, and the bending strength and the adhesion strength between the core material and the fiber reinforcing material can be obtained. Improved fiber reinforced molded body.

In addition, by setting the compression ratio C and the resin ratio R defined by the above formulas (A1) and (B1) to 200 to 5000% and 50 to 80%, respectively, it is possible to reduce the minute amount contained in the fiber-reinforced molded product. The size of the gap. In addition, when the resin foam is used as the core member 11A, the foamed resin of the resin foam dispersed in the thermosetting resins 11B and 21B is used. The uniformity of the skeleton is increased to uniformize the strength of the fiber-reinforced molded body. That is, the weakened portion of the fiber-reinforced molded body disappears. In this case, when the resin foam is cured in a compressed state to produce a fiber-reinforced molded product, the distance between the skeletons of the resin foams is smaller than the distance between the skeletons before compression, and the skeleton of the resin foam is also fibers. The reinforced molded body has a flat shape in the thickness direction.

According to the manufacturing method of the first (4) embodiment, the fiber-reinforced molded product in which the porous sheet 25 is disposed on both surfaces of the laminated body 10D can be easily produced. Therefore, it is suitable to use both surfaces as the design surface. Fiber reinforced molded body.

(Modification)

Furthermore, in the description of the manufacturing method of the above-mentioned first (4) embodiment, in the laminating step, the core fabric member 11A is laminated on the core material member 11A so that the impregnated fiber web 21C contacts the core material member 11A. The prepreg 20 is not limited to this.

As shown in the modification of Fig. 7, the fiber fabric 21C impregnated with one prepreg 20 may be in contact with the core member 11A, and the porous sheet 25A of the other prepreg 20 may be in contact with the core member 11A. The prepreg 20 is laminated on both surfaces of the core member 11A to form a laminated body 10E. In the fiber-reinforced molded product of the modified example, the core material 11 is a layer of a core member for the core material 11A and the porous sheet 25A (the resin foam for the core material) Layer). In the fiber-reinforced molded product, the core material 11 may be composed of a plurality of core material members (resin foam for core material).

Further, the method for producing a fiber-reinforced molded article according to this modification is suitable for a fiber-reinforced molded article in which only one side is used as a design surface. Further, since it is not necessary to separately prepare the prepreg 20 and the impregnated carbon fiber woven fabric 21C, the manufacturing cost can be reduced. Further, since one surface of the fiber-reinforced molded product is covered with the fiber-reinforced material, a fiber-reinforced molded body having a desired bending rigidity can be obtained.

In the impregnation step, the thermosetting resins 11B and 21B are impregnated into at least one of the core member 11A and the fiber fabric 21A, and the thermosetting resins 11B and 21B are not impregnated in the impregnation step. In the porous sheet 25A, the thermosetting resins 11B and 21B are further impregnated into the porous sheet 25A in the subsequent heat compression step. Therefore, the porous sheet 25A can be laminated without looseness in the laminating step, and wrinkles can be prevented from occurring.

Further, as shown in FIG. 2, when the coating film 27 is provided on the surface of the surface material 25, after the compression heating step in each embodiment, a coating step is performed to form a coating film 27 on the surface of the surface material 25. In the coating step, the surface of the surface material 25 is applied by spray coating, coater coating, dip coating, or the like, and then dried to form the coating film 27 on the surface of the surface material. The coating material is not particularly limited, and examples thereof include an urethane type, an acrylic type, a polyester type, and a vinyl acetate type, and a specific film thickness of, for example, a film thickness of about 5 to 40 μm. The coating is carried out in a manner.

As described above, according to one aspect of the present invention, a fiber-reinforced molded article comprising a core material, a fiber reinforcing material laminated on at least one surface of the core material, and a layer laminated on the fiber reinforcing material a surface material obtained by integrating the core material with the fiber reinforcing material and the surface material; and the fiber reinforcing material has a fiber woven fabric and a hardened thermosetting resin impregnated in the fiber fabric, the surface material a porous sheet having continuous cells and having a number of micropores of 8 to 80/25 mm and a thermosetting resin which is immersed in the porous sheet and cured, wherein the surface roughness Rz of the surface material is Below 30 μm.

According to the fiber-reinforced molded article of the present invention described above, the thermosetting resin is easily ooze out to the surface through the continuous bubbles of the surface material, so that the surface of the surface material is formed of a thermosetting resin which forms a smooth surface. Thereby, the surface roughness of the surface material can be made 30 μm or less, and a fiber-reinforced molded product having a small surface roughness and a good appearance can be obtained.

Moreover, since most of the smooth surface is a thermosetting resin which oozes out from the porous sheet, it is integrated with the fiber-reinforced molded body, and there is no case where it is peeled off together with the coating film. Moreover, since the adhesion between the thermosetting resin and the coating film is high, the fiber-reinforced molded article of the present invention exhibits good coating film adhesion.

Moreover, according to one aspect of the present invention, a method of producing a fiber-reinforced molded article, comprising: a core material having a member for a core material, laminated on at least one side of the core material and having a fiber fabric A method for producing a fiber-reinforced material and a fiber-reinforced molded product having a surface layer of a porous sheet laminated on the fiber-reinforced material; and comprising the step of impregnating the core with a thermosetting resin And at least one of the material member and the fiber fabric; and a laminating step of sequentially laminating the fiber fabric and the number of micropores of 8 to 80/25 mm and a thickness of 0.4 on at least one surface of the core member. a porous sheet having a continuous bubble of ~3.0 mm; and a compression heating step of heating the surface of the core member, the fiber fabric, and the porous sheet while compressing, thereby making the thermosetting property The resin is impregnated into the core member, the fiber woven fabric, and the porous sheet, and is cured to cause the core material, the fiber reinforced material, and the surface material Body of.

According to the method for producing a fiber-reinforced molded article of the present invention, as described above, the fiber-reinforced molded article having excellent appearance can be obtained relatively easily.

Furthermore, according to another aspect of the present invention, a fiber-reinforced molded article comprising a core material having a member for core material containing continuous cells, laminated on both sides of the core material and having a fiber fabric can be provided. a fiber-reinforced material, and a surface material of the porous sheet which is laminated on the fiber-reinforced material, and the core material, the fiber-reinforced material, and the surface material are integrated by a thermosetting resin; In the core material, the thermosetting resin is impregnated into the core member, and the thermosetting resin is cured in a state where the core member is compressed, and the compression ratio defined by the following formula (A1) is included. When C is in the range of 200 to 5000%, the resin ratio R of the thermosetting resin specified by the following formula (B1) is in the range of 50 to 80%, and the flexural modulus of the fiber-reinforced molded article is 30 GPa or more.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

R=(Wb-Wa)/Wb×100 (B1)

(Wa: the total weight of the core material member, the fiber woven fabric, and the porous sheet, Wb: the total weight of the core member, the fiber woven fabric, and the porous sheet after impregnating the thermosetting resin, R: resin ratio).

In the above fiber-reinforced molded product, the porous sheet may include a urethane resin foam from which a microporous film is removed.

In the fiber-reinforced molded product, the core member may include a urethane resin foam or a melamine resin foam.

In the fiber-reinforced molded product, the core member may be impregnated with the thermosetting resin selected from the group consisting of an epoxy resin, a phenol resin, and a mixture of an epoxy resin and a phenol resin.

In the fiber-reinforced molded product, the fiber-reinforced material may be impregnated with the thermosetting resin selected from the group consisting of an epoxy resin, a phenol resin, and a mixture of an epoxy resin and a phenol resin.

In the fiber-reinforced molded product, the core material member and the fiber-reinforced material may be impregnated with the thermosetting resin containing the same material.

In the fiber-reinforced molded product, the compression ratio C defined by the above formula (A1) may be 1000 to 2600%.

In the fiber-reinforced molded product, the ratio of the thickness of the porous sheet before compression of the surface material to the total thickness of the core member and the porous sheet before compression of the core material may be 2 ~30%.

According to the fiber-reinforced molded product of the present invention, since the resin ratio and the compression ratio are set to a specific range, the fiber-reinforced molded article having high rigidity can be easily provided. Moreover, by attaching the thermosetting resin to the continuous cell structure of the core member, the thermosetting resin can be uniformly dispersed in the core member. When the thermosetting resin is cured in this state, the thermosetting resin can be densely filled in the member for core material, and a fiber-reinforced molded product in which the bending strength and the adhesion strength between the core material and the fiber-reinforced material are improved can be obtained.

Furthermore, according to another aspect of the present invention, a method of producing a fiber-reinforced molded article comprising a core material having a member for core material containing continuous cells and laminated on both surfaces of the core material A method for producing a fiber-reinforced structure having a fiber-reinforced material of a fiber woven fabric and a surface material of a porous sheet having continuous bubbles formed on at least one surface of the fiber-reinforced material; comprising the following steps: an impregnation step The thermosetting resin is impregnated into at least one of the core material member and the fiber fabric; and the laminating step is to laminate the fiber fabric on both sides of the core material member, and at least the laminated fiber fabric is laminated a porous sheet which is laminated on one side; and a compression heating step of impregnating the thermosetting resin by heating against the core member, the fiber fabric, and the porous sheet And curing the core material member, the fiber woven fabric, and the porous sheet to form the core material and the fiber The reinforcing material and the surface material are integrated; the impregnation in the impregnation step is performed in such a manner that the resin ratio R defined by the following formula (B1) is in the range of 50 to 80%, and the compression in the compression heating step is performed by The compression ratio C specified by the following formula (A1) is 200 to 5000%.

C=(Tb-Ta)/Ta×100 (A1)

(Ta: thickness of the member for core material after compression, Tb: thickness of the member for core material before compression, C: compression ratio)

R=(Wb-Wa)/Wb×100 (B1)

(Wa: the total weight of the core material member, the fiber woven fabric, and the porous sheet, Wb: the total weight of the core member, the fiber woven fabric, and the porous sheet after impregnating the thermosetting resin, R: resin ratio).

In the method for producing a fiber-reinforced molded article, the core member may have a compression ratio of 1,000 to 2,600%.

In the method for producing a fiber-reinforced molded article, the porous sheet may include a urethane resin foam from which a microporous film is removed.

In the method for producing a fiber-reinforced molded article, in the impregnation step, the thermosetting resin containing the same material may be impregnated into both the core member and the fiber fabric.

In the method for producing a fiber-reinforced molded article, in the stacking step, two prepregs in which the fiber fabric impregnated with the thermosetting resin and the porous sheet are laminated to form the fiber fabric The prepreg is laminated on both surfaces of the core member for contact with the core member.

In the method for producing a fiber-reinforced molded article, in the stacking step, two prepregs in which the fiber fabric impregnated with the thermosetting resin and the porous sheet are laminated may be prepared to make one of the above-mentioned pre-pregs The fiber woven fabric of the immersion body is in contact with the core material member, and the porous sheet of the other prepreg is brought into contact with the core material member to be laminated on both surfaces of the core material member. The above prepreg.

In the method for producing a fiber-reinforced molded product, the thickness of the porous sheet before compression of the surface material is a ratio of the thickness of the core member to the total thickness of the porous sheet before compression of the core material. Can be 2~30%.

According to the method for producing a fiber-reinforced molded article of the present invention, as described above, it is possible to easily obtain a fiber-reinforced molded article having high rigidity and high bending strength and improved adhesion strength between the core material and the fiber-reinforced material.

[Examples]

Next, the fiber-reinforced molded product of Examples 1-1 to 1-9 was produced by the above-described production method according to the first (3)th embodiment of the present invention, and the first (4) embodiment of the present invention and its modification EXAMPLES Production Method The fiber-reinforced molded articles of Examples 1-10 and 1-11 were produced and compared with the fiber-reinforced molded articles of Comparative Examples 1-1 to 1-3.

‧Example 1-1

A phenol resin (trade name: PADS-4 manufactured by Asahi Organic Materials Co., Ltd. and Hexam Organic Tetrachloride, manufactured by Asahi Organic Materials Co., Ltd.) The thermosetting resin was dissolved in methanol so as to have a concentration of 30 wt%. A carbon fiber fabric (manufactured by Toho Tenax Co., Ltd., trade name: W-3101, fiber weight: 200 g/m ² ) which is a plain fabric of a fiber fabric was impregnated in the phenol resin solution, and taken out at a room temperature of 25 ° C after being taken out. It was dried for 2 hours and further dried at 60 ° C for 1 hour to form 2 sheets of impregnated fiber fabric. Carbon fiber fabrics were cut to a flat size of 200 x 300 mm (weight 12 g/piece). The dried impregnated fiber fabric was 28 g per piece.

Further, as a member for a core material, a melamine resin foam having a continuous bubble formed by a thickness of 10 mm and a plane size of 200 × 300 mm (weight 5.4 g) was produced in the same manner as the fiber fabric (manufactured by BASF Corporation). , product name: Basotect V3012, density 9 kg / m ³ ) immersed in the phenol resin solution, removed and naturally dried at room temperature of 25 ° C for 2 hours, and then dried in an environment of 60 ° C for 1 hour to form an impregnation A member for a core material. The weight of the hot component for the impregnated core material after drying was 27 g. Further, the ratio of the resin contained in the entire fabric member and the member for core material was 65%.

Next, the impregnated fiber fabric, the impregnated core material member, and the impregnated fiber are placed in this order on the lower mold (flat plate shape) for extrusion molding which is previously coated with a release agent on the surface. a woven fabric or a porous sheet, whereby the impregnated fiber fabric is disposed on both sides of the impregnated core member, and further disposed on the surface of the impregnated fiber fabric on one side of the impregnated core member The laminate having the porous sheet is placed on the lower mold for extrusion molding.

As the porous sheet, a urethane resin foam (manufactured by Inoac Corporation, trade name: MF-50, loose specific gravity: 0.03, and a number of micropores of 50 per unit) which removes the microporous membrane by a dissolution treatment is used. 25 mm) Cut to an uncompressed thickness of 0.4 mm. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the core member was 4%. Further, the void ratio of the urethane resin foam used was 97.1%. The calculation formula of the void ratio is as follows. Void ratio (%) = (actual specific gravity of urethane resin - bulk specific gravity (visual density of urethane resin foam)) / actual specific gravity of urethane resin × 100

In the state in which the laminated body was placed on the lower mold for extrusion molding, the laminate was pressed at a temperature of 180 ° C by a top mold (flat plate shape) of 5 MPa for 3 minutes to perform compression and heating. The phenol resin is reacted and hardened under compression. The heating of the laminate at this time is performed by a casting heater attached to the upper and lower extrusion dies.

Further, a spacer made of SUS having a thickness of 0.9 mm was inserted between the lower mold for extrusion molding and the upper mold to adjust the interval between the lower mold and the upper mold, that is, the compressed thickness of the laminated body. Thereafter, after the lower mold and the upper mold for extrusion molding are cooled at room temperature, the lower mold and the upper mold are opened, and a fiber reinforcing material is laminated on both sides of the core material, and the fiber reinforcing material is further laminated on one side. A fiber-reinforced molded body in which a surface material formed of a porous sheet is laminated and integrated. The fiber-reinforced molded product was cut into 170 × 260 mm to prepare a fiber-reinforced molded product of Example 1-1.

‧Example 1-2

A fiber-reinforced molded product of Example 1-2 was produced in the same manner as in Example 1-1 except that the thickness (the thickness in the uncompressed state) of the porous sheet of Example 1-1 was 0.6 mm. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the core member was 6%.

‧Examples 1-3

A fiber-reinforced molded product of Example 1-3 was produced in the same manner as in Example 1-1, except that the thickness (the thickness in the uncompressed state) of the porous sheet of Example 1-1 was 1.0 mm. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the member for the core material was 10%.

‧Examples 1-4

A fiber-reinforced molded product of Example 1-4 was produced in the same manner as in Example 1-1 except that the thickness (the thickness in the uncompressed state) of the porous sheet of Example 1-1 was 2.0 mm. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the core member was 20%.

‧Examples 1-5

A fiber-reinforced molded product of Example 1-5 was produced in the same manner as in Example 1-1, except that the thickness (the thickness in the uncompressed state) of the porous sheet of Example 1-1 was 3.0 mm. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the core member was 30%.

‧Examples 1-6

A urethane resin foam obtained by a dissolution treatment to remove a microporous membrane using a void ratio of 95.2% and a thickness of 1.0 mm when not compressed (manufactured by Inoac Corporation, trade name: MF-80, pine) A fiber-reinforced molded article of Example 1-6 was produced in the same manner as in Example 1-1, except that the porous sheet of Example 1-1 was used instead of the porous sheet of Example 1-1. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the member for the core material was 10%.

‧Examples 1-7

A urethane resin foam obtained by dissolving a microporous film by a dissolution treatment using a void ratio of 97.3% and a thickness of 1.0 mm when not compressed (manufactured by Inoac Corporation, trade name: MF-10, pine) The fiber-reinforced molded product of Example 1-7 was produced in the same manner as in Example 1-1 except that the porous sheet of Example 1-1 was used instead of the porous sheet of the example 1-1. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the member for the core material was 10%.

‧Examples 1-8

A urethane resin foam obtained by dissolving a microporous film by a dissolution treatment using a void ratio of 97.4% and a thickness of 1.0 mm at the time of non-compression (manufactured by Inoac Corporation, trade name: MF-8, pine) The fiber-reinforced molded product of Example 1-8 was produced in the same manner as in Example 1-1, except that the porous sheet of Example 1-1 was used instead of the porous sheet of Example 1-1. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the member for the core material was 10%.

‧Examples 1-9

A urethane resin foam having a microporous membrane which has a porosity of 97.0% and a thickness of 1.0 mm which is not subjected to microporous membrane removal treatment (manufactured by Inoac Corporation, trade name: SP) A fiber of Example 1-9 was produced in the same manner as in Example 1-1 except that the porous sheet of Example 1-1 was replaced by -50, a bulk specific gravity of 0.031 and a number of micropores of 50 / 25 mm. Strengthen the molded body. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the member for the core material was 10%.

‧Examples 1-10

A phenol resin (manufactured by DIC Corporation, trade name: Phenolite 5010, solid content 60%) which is a thermosetting resin for reinforcing material was mixed in ethanol so as to be 50 wt%. The phenol resin solution was immersed in a carbon fiber fabric of a plain weave fabric (manufactured by Toho Tenax Co., Ltd., trade name: W-3101, fiber weight: 200 g/m ² ), and a porous sheet was placed thereon (Inoac Corporation, Inc.) Manufactured, trade name: MF-50LE, bulk specific gravity 0.03, number of micropores 50 / 25 mm) to obtain a prepreg.

The porous sheet was cut into a non-compressed state by a thickness of 0.7 mm using a urethane resin foam obtained by removing a microporous film by a dissolution treatment. Further, the void ratio of the urethane resin foam used was 97.1%. The calculation formula of the void ratio is as follows.

Void ratio (%) = (actual specific gravity of urethane resin - bulk specific gravity ( Urethane resin foam apparent density)) / urethane resin actual specific gravity × 100

Further, the carbon fiber fabric used was 380 × 260 mm (weight 19.8 g / tablet). The dried carbon fiber fabric after drying was 36 g per one piece. The two prepregs thus obtained were dried in an environment of 87 ° C for 5 minutes.

As a member for a core material, a melamine resin foam having a continuous bubble formed by a thickness of 7.5 mm and a plane size of 380 × 260 mm (weight: 6.0 g/piece) was produced in the same manner as the carbon fiber (trade name, manufactured by BASF Corporation). : Basotect V3012, density 9 kg/m ³ ) was immersed in a phenol resin solution, taken out and dried in an environment of 100 ° C for 31 minutes to form a member for impregnation of the core material. The weight of the member for impregnation of the core material after drying was 67 g. Moreover, the ratio of the resin contained in the carbon fiber woven fabric and the thermosetting resin foam was 64%.

Next, a prepreg having a porous sheet surface as an upper side and a thermosetting resin which has been impregnated are sequentially laminated on a flat-shaped lower mold for extrusion molding by a SUS-prepared release agent. The foam body and the prepreg having the porous sheet surface as the upper side were obtained to obtain a laminate. In other words, the laminate has a fiber woven fabric, a porous sheet, a member for a core material, a fiber woven fabric, and a porous sheet in this order from bottom to top. This laminated body was placed on the lower mold for extrusion molding. In addition, the ratio of the thickness of the porous sheet which becomes a surface material to the total thickness of the porous sheet which becomes a core material, and the member for core materials is 9%.

In the state in which the laminated body was placed on the lower mold for extrusion molding, the laminate was pressed at 145 ° C by a surface pressure of 5 MPa by an upper mold for extrusion (plate shape), and the laminate was pressed for 8 minutes to be compressed and heated. The phenol resin is reacted and hardened in the above compressed state.

The heating of the laminate at this time is carried out by means of a casting heater mounted on the upper and lower extrusion dies. Further, the compression thickness of the laminated body was adjusted by providing a gap of 1.0 mm between the lower mold for extrusion molding and the upper mold. Thereafter, the lower mold and the upper mold are opened, and a fiber reinforcing material is laminated on both sides of the core material, and the surface material formed of the porous sheet is laminated on the fiber reinforcing material on one side and integrated. Strengthen the molded body.

‧Examples 1-11

A prepreg obtained in the same manner as in the above-mentioned Example 1-10 was used, and a porous sheet was sequentially laminated on a lower mold (flat shape) for extrusion molding which was previously coated with a release agent on a surface. The material was a prepreg on the lower side, a thermosetting resin foam impregnated, and a prepreg having the porous sheet as the upper side to obtain a laminate. In other words, the laminated system has a porous sheet, a fiber woven fabric, a member for a core material, a fiber woven fabric, and a porous sheet in this order from bottom to top. This laminated body was placed on the lower mold for extrusion molding. In addition, the ratio of the total thickness of the porous sheet which becomes a surface material to the thickness of the member for core materials was 19 %.

In the state in which the laminated body was placed on the lower mold for extrusion molding, the laminate was subjected to compression and heating for 8 minutes by applying a surface pressure of 5 MPa to the upper mold (flat plate shape) for extrusion molding at 145 °C. The phenol resin is reacted and hardened under compression. The heating of the laminate at this time is performed by a casting heater attached to the upper and lower extrusion dies. Further, the compression thickness of the laminated body was adjusted by providing a gap of 1.0 mm between the lower mold for extrusion molding and the upper mold.

Thereafter, the lower mold and the upper mold are opened, and a fiber-reinforced material is laminated on both sides of the core material, and a surface-formed material formed of a porous sheet is laminated on the fiber-reinforced material to form a fiber-reinforced molded body. .

‧Comparative Example 1-1

The porous sheet of the surface of Example 1-1 was removed, and the fiber-reinforced molded product of Comparative Example 1-1 was produced.

‧Comparative Example 1-2

A fiber-reinforced molding of Comparative Example 1-2 was produced in the same manner as in Example 1-1 except that the thickness (the thickness in the uncompressed state) of the porous sheet of the surface in Example 1-1 was 4.0 mm. body. The ratio of the total thickness of the porous sheets which are the surface materials to the total thickness of the members for the core material was 40%.

‧Comparative Example 1-3

A urethane resin foam obtained by dissolving a microporous film by a dissolution treatment using a void ratio of 92.8% and a thickness of 1.0 mm when not compressed (manufactured by Inoac Corporation, trade name: MF-100, pine) A fiber-reinforced molded product of Comparative Example 1-3 was produced in the same manner as in Example 1-1 except that the porous sheet of Example 1-1 was used instead of the porous sheet of Example 1-1. .

For each of the examples and comparative examples, the overall thickness before coating and the flexural modulus (JIS K7074-1988 A method, fiber direction) and the surface roughness of the surface material were measured. The surface roughness was measured by a surface roughness meter (manufactured by Tokyo Precision, trade name: Surfcom 113A), and the surface roughness of the surface was measured at a standard length of 20 mm (RzJIS82). RzJIS82 is the tenth point average roughness of the old specification JIS B0601:1982. In the profile curve of the standard length, it is the highest from the highest peak to the fifth peak height in descending order. The shallow order is the sum of the average values from the deepest valley bottom to the fifth valley depth. The measurement results are shown in Table 1.

Further, for each of the examples and the comparative examples, a two-liquid-curing urethane-based paint was applied to the surface of the surface material (the surface of the fiber woven fabric in Comparative Example 1-1), and the film was spray-coated. Coating was carried out so as to have a thickness of 20 μm to form a coating film, and the appearance of the coating, the surface roughness of the coated surface, and the coating adhesion were examined.

The appearance of the coating refers to the appearance of the coating film, and the surface of the coating film after drying is visually observed, and the case where the unevenness is not observed at all is judged as E (Excellent), and the case where the unevenness is slightly observed is judged as G (Good). The case where the unevenness can be clearly observed is judged as B (Bad).

The surface roughness of the coated surface was measured by a surface roughness meter (manufactured by Tokyo Seiko Co., Ltd., trade name: Surfcom), and the surface of the coated film after drying was measured for Rz at 10 points, and the average surface roughness (μm) was expressed. .

The term "coating adhesion" refers to the adhesion of the coating film. On the surface of the coating film after drying, 100 square-shaped slits (cross-cutting) are formed at intervals of 1 mm using a dicing blade, and 100 of the slits are formed. The square portion was followed by a scotch tape having a width of 25 mm and a length of 75 mm, and thereafter the scotch tape was peeled off, and the coating adhesion was indicated by the number of unpeeled coating films (closed number). The measurement results are shown in Table 1.

Examples 1-1 to 1-9 in which a porous sheet (surface material) was provided on the surface, compared with Comparative Example 1-1 in which a porous sheet was not provided on the surface, surface roughness before coating and after coating The surface roughness is small, the coating appearance is good, the coating adhesion is good, and the coating film is not easily peeled off. In particular, when Comparative Example 1-1 was compared with Comparative Example 1-1 only in the presence or absence of the porous sheet, Comparative Example 1-1 without the porous sheet was before and after application. The surface roughness is greater than twice the surface roughness of Example 1-1 having a porous sheet before and after application, and the coating appearance and coating adhesion are also significantly inferior to Comparative Example 1-1.

Further, when Examples 1 to 3 of the microporous film from which the porous sheet was removed were compared with Examples 1 to 9 in which the microporous film of the porous sheet was not removed, Examples 1-3 in which the microporous film was removed were removed. The surface roughness before and after application is less than one-half of the surface roughness of the examples 1-9 before and after the removal of the microporous film, that is, the unevenness is extremely small. Moreover, the coating appearance and the coating adhesion were also superior to those of Examples 1-9.

Further, Comparative Example 1-2, which was the same as Example 1 except that the thickness of the porous sheet (thickness in the uncompressed state) was changed from the thickness of 0.4 mm of Example 1-1 to the thickness of 4.0 mm, and the same was carried out. In comparison with Example 1-1, the flexural modulus is about one-half, and the surface roughness before and after application is nearly twice the value, that is, the unevenness is extremely large, and the coating appearance and coating are applied. The adhesion was inferior to Example 1-1. In addition, the ratio of the total thickness of the porous sheet before compression of the surface material to the total thickness of the core member and the porous sheet before compression of the core material is 4% to 30%. 1 to 1-11 has a larger bending elastic modulus than Comparative Example 1-2 in which the ratio is 40%.

Comparative Example 1-3 in which the number of micropores of the porous sheet was set to 100 / 25 mm and Example 1-3 except the number of micropores (the number of micropores was 50 / 25 mm), Example 1 -6 (number of micropores 80 / 25 mm), examples 1-7 (number of micropores 10 / 25 mm) and examples 1-8 (number of micropores 8 / 25 mm), before coating And the surface roughness after coating is about 2 times to about 4 times, that is, the unevenness is extremely large, and the coating appearance and coating adhesion are also inferior to Examples 1-3, 1-6, 1-7. And 1-8.

Further, no significant difference was observed between Examples 1-1 to 1-9 and Examples 1-10 and 1-11. Therefore, it has been confirmed that the fiber-reinforced molded article having excellent coating appearance and coating adhesion can be obtained by impregnating at least one of the core member and the fiber fabric with a thermosetting resin, and then laminating each of the following methods. a member; or a prepreg made of a fiber fabric and a porous sheet, and a prepreg layer is laminated on the member for the core material.

As described above, the embodiment of the present invention has a thin wall and a high rigidity, and is excellent in appearance and coating without peeling off the coating film, and is suitable for use as a casing of a mobile device such as a notebook computer. Further, depending on the use of the fiber-reinforced molded product, the fiber reinforcing material and the surface material may be provided only on one side of the core material.

Here, in order to obtain a thin-walled fiber-reinforced molded product, it is necessary to reduce the thickness of the resin foam for core material which functions as a spacer for adjusting the thickness of the core material while maintaining the curable resin. However, if the resin foam for core material is directly used as a core material without being compressed, there are the following two problems.

a. The resin foam used for the resin foam for core materials is difficult to cut thinly and uniformly. In particular, when the resin foam resin foam for a core material is cut thin, the thickness thereof tends to be uneven.

b. When the cross section of the resin foam resin foam for a core material to be cut is observed in an uncompressed state, a cross section of the foam having a microporous skeleton and a cross section without a microporous skeleton are mixed in the longitudinal direction. Therefore, when the fiber-reinforced molded product is molded without being compressed, the resin ratio of the thermosetting resin in each cross section is different, and the overall bending elastic modulus is lowered by the influence of the weaker cross section.

Therefore, in the fiber-reinforced molded product of the present invention, the resin foam for core material used as the resin foam for core material is processed and compressed in a relatively thick state, whereby the following effects can be obtained.

‧ The unevenness of the thickness of the resin foam for the core material is inversely proportional to the compression ratio.

‧ In the resin foam body for core materials, the microporous skeleton in a state of being randomly laminated is superposed by compression, so that the unevenness of the resin ratio in each cross section is reduced.

‧ The resin foam for thick core material is easily impregnated with thermosetting resin.

Therefore, in the fiber-reinforced molded product of the embodiment described below, the resin foam for core material is used in a state where the thickness is thick, and compression is performed in a state in which the thermosetting resin is impregnated, and the compression ratio is obtained. And the impregnation amount is set within a specific range. Hereinafter, it demonstrates concretely.

[Examples]

The fiber-reinforced molded product of Example 2-8 was produced by the above-described production method of the first (1) embodiment of the present invention, and Examples 2-9 were produced by the production method of the first (2)th embodiment of the present invention. In the fiber-reinforced molded product, the fiber-reinforced molded articles of Examples 2-1 to 2-7 and 2-10 to 2-14 are produced by the production method of the first (3)th embodiment of the present invention, and the present invention is 1-(4) Production method of the embodiment The fiber-reinforced molded articles of Examples 2-15 and 2-16 were produced and compared with the fiber-reinforced molded articles of Comparative Examples 2-1 to 2-10.

‧Example 2-1

A phenol resin (trade name: PAPS-4 manufactured by Asahi Organic Materials Co., Ltd. and hexamethylenetetramine manufactured by Asahi Organic Materials Co., Ltd.) The thermosetting resin was dissolved in methanol so as to have a concentration of 30 wt%. A fiber fabric (carbon fiber fabric, manufactured by Toho Tenax Co., Ltd., trade name: W-3101, fiber weight 200 g/m ² ) impregnated with the phenol resin solution, taken out and naturally dried at room temperature of 25 ° C After 2 hours, it was further dried at 60 ° C for 1 hour to form 2 sheets of impregnated fiber fabric. The fabric was cut to a flat size of 200 x 300 mm (weight 12 g/piece). The dried impregnated fiber fabric was 28 g per piece.

Further, as a resin foam for a core material, a melamine resin foam having a continuous bubble formed by cutting into a thickness of 10 mm and a plane size of 200 × 300 mm (weight: 5.4 g) was used in the same manner as the fiber fabric (BASF). Made by the company, the product name: Basotect V3012, density 9 kg / m ³ ) immersed in the phenol resin solution, taken out and naturally dried at room temperature of 25 ° C for 2 hours, and then dried in an environment of 60 ° C for 1 hour to form Resin foam for core material. The weight of the resin foam for impregnated core material after drying was 27 g. In addition, the ratio of the resin (the value calculated by the formula (B1) based on the resin ratio) contained in the entire resin foam of the fiber woven fabric and the core material was 65%.

Next, the impregnated fiber fabric, the impregnated resin foam for the core material, and the impregnation are placed in this order on the lower mold (plate shape) for extrusion molding which is previously coated with a release agent on the surface. The fiber woven fabric and the porous sheet are obtained by disposing the impregnated fiber woven fabric on both sides of the impregnated resin foam for core material, and further on one side of the resin foam for impregnating the core material. A layered body in which a porous sheet is disposed on the surface of the impregnated fiber fabric on the surface, and the layered body is placed on the lower mold for extrusion molding.

As the porous sheet, a urethane resin foam (manufactured by Inoac Corporation, trade name: MF-50, loose specific gravity: 0.03, and a number of micropores of 50 per unit) which removes the microporous membrane by a dissolution treatment is used. 25 mm) Cut to an uncompressed thickness of 0.4 mm. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the core member was 4%. Further, the void ratio of the urethane resin foam used was 97.1%. The calculation formula of the void ratio is as follows. Void ratio (%) = (actual specific gravity of urethane resin - bulk specific gravity (visual density of urethane resin foam)) / actual specific gravity of urethane resin × 100

In the state in which the laminated body was placed on the lower mold for extrusion molding, the laminate was pressed at a temperature of 180 ° C by a top mold (flat plate shape) of 5 MPa for 3 minutes to perform compression and heating. The phenol resin is reacted and hardened under compression. The heating of the laminate at this time is performed by a casting heater attached to the upper and lower extrusion dies. Further, a spacer made of SUS having a thickness of 0.9 mm was inserted between the lower mold for extrusion molding and the upper mold to adjust the interval between the lower mold and the upper mold, that is, the compressed thickness of the laminated body.

Thereafter, after the lower mold and the upper mold for extrusion molding are cooled at room temperature, the lower mold and the upper mold are opened, and a fiber reinforcing material is laminated on both sides of the core material, and the fiber reinforcing material is further laminated on one side. A fiber-reinforced molded body in which a surface material formed of a porous sheet is laminated and integrated. The fiber-reinforced molded product was cut into 170 × 260 mm to prepare a fiber-reinforced molded product of Example 2-1.

With respect to the fiber-reinforced molded product of Example 2-1, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the thermosetting resin foam constituting the core material is calculated by using the thickness of the resin foam for core material before compression (10 mm) and the thickness of the core material (0.43 mm) according to the formula of the compression ratio. It is 2225%. Further, in the fiber-reinforced molded product of Example 2-1, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 50 GPa (fiber direction).

‧Example 2-2

The thickness of the resin foam for the core material is set to 5 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the ratio (the value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 8%.

With respect to the fiber-reinforced molded product of Example 2-2, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.29, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for the core material was calculated by the formula of the compression ratio, and was 1062%, based on the thickness (5 mm) of the resin foam for core material before compression and the thickness of the core material (0.43 mm). Further, in the fiber-reinforced molded product of Example 2-2, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 49 GPa (fiber direction).

‧Example 2-3

The thickness of the resin foam for the core material is set to 11.5 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the ratio (the value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 3%.

With respect to the fiber-reinforced molded article of Example 2-3, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.32, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was 2513% as a function of the compression ratio, using the thickness of the resin foam for core material before compression (11.5 mm) and the thickness of the core material (0.44 mm). Further, with respect to the fiber-reinforced molded product of Example 2-3, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 51 GPa (fiber direction).

‧Examples 2-4

The thickness of the resin foam for the core material is set to 1.4 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the ratio (the value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 29%.

With respect to the fiber-reinforced molded product of Example 2-4, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.28, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for the core material was calculated by using the thickness of the resin foam for core material before compression (1.4 mm) and the thickness of the core material (0.43 mm), and found to be 225% based on the formula of the compression ratio. Further, in the fiber-reinforced molded product of Example 2-4, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 46 GPa (fiber direction).

‧Example 2-5

The thickness of the resin foam for the core material is set to 22 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the ratio (the value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 2%.

With respect to the fiber-reinforced molded product of Example 2-5, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.35, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was 4,900%, based on the thickness of the resin foam for the core material before compression (22 mm) and the thickness of the core material (0.44 mm). Further, in the fiber-reinforced molded product of Example 2-5, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 51 GPa (fiber direction).

‧Examples 2-6

The weight of each of the dried impregnated fiber fabrics was set to 35 g, and the weight of the impregnated core material resin foam after drying was set to 45 g, and the fiber fabric and the core material were foamed with the resin. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the resin ratio (the value calculated by the formula (B1) of the resin ratio) contained in the entire body was 74%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 4%.

With respect to the fiber-reinforced molded product of Example 2-6, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.45, the overall thickness is 1.0 mm, and the thickness of the core material is 0.52 mm. The compression ratio of the resin foam for the core material was 1823% as a function of the compression ratio using the thickness (10 mm) of the resin foam for core material before compression and the thickness of the core material (0.52 mm). Further, with respect to the fiber-reinforced molded product of Example 2-6, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 55 GPa (fiber direction).

‧Examples 2-7

The weight of each of the dried impregnated fiber fabrics was set to 22 g, and the weight of the impregnated core material resin foam after drying was set to 16 g, and the fiber fabric and the core material were foamed with the resin. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the resin ratio (the value calculated by the formula (B1) of the resin ratio) contained in the entire body was 51%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 4%.

With respect to the fiber-reinforced molded article of Example 2-7, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for a core material was 2225% based on the thickness of the resin foam for the core material before compression (10 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio. Further, with respect to the fiber-reinforced molded product of Example 2-7, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 45 GPa (fiber direction).

‧Examples 2-8

The weight of the fiber fabric which has been impregnated after drying is 40 g, and the resin foam for the core material does not contain the resin, and the ratio of the resin contained in the fiber foam to the resin foam for the core material (according to the resin ratio) A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the value calculated by the formula (B1) was 66%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 4%.

With respect to the fiber-reinforced molded article of Example 2-8, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for a core material was 2225% based on the thickness of the resin foam for the core material before compression (10 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio. Further, with respect to the fiber-reinforced molded product of Example 2-8, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 50 GPa (fiber direction).

‧Examples 2-9

The fiber fabric is not impregnated with the resin, and the weight of the resin foam for impregnating the core material after drying is 40 g, and the ratio of the resin contained in the entire resin foam of the fiber fabric and the core material (according to the resin ratio) A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the value calculated by the formula (B1) was changed to 54%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 4%.

With respect to the fiber-reinforced molded article of Example 2-9, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for a core material was 2225% based on the thickness of the resin foam for the core material before compression (10 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio. Further, with respect to the fiber-reinforced molded product of Example 2-9, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 46 GPa (fiber direction).

‧Example 2-10

A urethane resin foam having an open cell (manufactured by Inoac Corporation, Moltopren MF80, density: 72 kg/m ³ ) was used as a resin foam for a core material, and a thermosetting resin was adjusted for the core material. The amount of impregnation in the resin foam is set to 65% by the resin ratio (the value calculated by the formula (B1) of the resin ratio) contained in the entire resin foam of the core material, and In the same manner as in Example 2-2, a fiber-reinforced molded product was obtained. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 8%.

With respect to the fiber-reinforced molded product of Example 2-10, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.35, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was calculated by the formula of the compression ratio using a thickness (5 mm) of the resin foam for core material before compression and a thickness of the core material (0.44 mm), and found to be 1036%. Further, with respect to the fiber-reinforced molded product of Example 2-10, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 35 GPa (fiber direction).

‧Example 2-11

In addition to using an epoxy resin (a product name: Epiclon 850 manufactured by DIC Co., Ltd. and a trade name of WH-108S manufactured by DIC Co., Ltd. at a ratio of 100:30), as a thermosetting resin, In the same manner as in Example 2-1, a fiber-reinforced molded product was obtained. The resin ratio (value calculated based on the formula (B1) of the resin ratio) contained in the entire resin foam of the fiber woven fabric and the core material was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 4%.

With respect to the fiber-reinforced molded product of Example 2-11, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for the core material constituting the core material is calculated by using the thickness of the resin foam for core material before compression (10 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio. It is 2225%. Further, in the fiber-reinforced molded product of Example 2-11, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 49 GPa (fiber direction).

‧Example 2-12

A melamine resin foam (manufactured by BASF, trade name: Basotect V3012, density 9 kg/m ³ ) with continuous air bubbles cut to a thickness of 2.2 mm and a plane size of 200 × 300 mm (1.2 g weight) was used as the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except for the resin foam. Further, the weight of the resin foam for core material which had been impregnated after drying was 16 g. In addition, the ratio of the resin (the value calculated by the formula (B1) based on the resin ratio) contained in the entire resin foam of the fiber woven fabric and the core material was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 18%.

With respect to the fiber-reinforced molded product of Example 2-12, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.28, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for a core material was 411%, which was calculated from the formula of the compression ratio, using the thickness (2.2 mm) of the resin foam for core material before compression and the thickness of the core material (0.43 mm). Further, in the fiber-reinforced molded product of Example 2-12, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 46 GPa (fiber direction).

‧Example 2-13

The thickness of the resin foam for the core material is set to 3 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-12 except that the ratio was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 13%.

With respect to the fiber-reinforced molded product of Example 2-13, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.29, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for a core material was calculated to be 597% based on the thickness of the resin foam for the core material before compression (3 mm) and the thickness of the core material (0.43 mm). Further, with respect to the fiber-reinforced molded product of Example 2-13, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 47 GPa (fiber direction).

‧Example 2-14

The thickness of the resin foam for the core material is set to 4 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-12 except that the ratio was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 10%.

With respect to the fiber-reinforced molded product of Example 2-14, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.29, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for the core material was 830% based on the thickness of the resin foam for the core material before compression (4 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio. Further, with respect to the fiber-reinforced molded product of Example 2-14, the bending elastic modulus (JIS K7074) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 49 GPa (fiber direction).

‧Examples 2-15

A phenol resin (manufactured by DIC Corporation, trade name: Phenolite 5010, 60% solid content) was mixed in ethanol so as to be 50 wt%. The phenol resin solution was immersed in a carbon fiber fabric (manufactured by Toho Tenax Co., Ltd., trade name: W-3101, fiber weight: 200 g/m ² ) of a plain woven fabric, and a porous sheet was placed thereon (Inoac Co., Ltd.) A prepreg was obtained from Corporation, trade name: MF-50LE, bulk specific gravity 0.03, and number of micropores 50/25 mm.

The porous sheet was cut into a non-compressed state by a thickness of 0.7 mm using a urethane resin foam obtained by removing a microporous film by a dissolution treatment. Further, the void ratio of the urethane resin foam used was 97.1%. The calculation formula of the void ratio is as follows.

Void ratio = (actual specific gravity of urethane resin - bulk specific gravity (visual density of urethane resin foam)) / actual specific gravity of urethane resin × 100

Further, the carbon fiber fabric was used in a size of 380 × 260 mm (weight: 19.8 g / tablet). The dried carbon fiber fabric after drying was 36 g per one piece.

The two prepregs thus obtained were dried in an environment of 87 ° C for 5 minutes.

As a resin foam for a core material, a melamine resin foam having a continuous bubble formed by a thickness of 7.5 mm and a plane size of 380 × 260 mm (weight: 6.0 g/piece) was produced in the same manner as the carbon fiber (manufactured by BASF Corporation). The product name: Basotect V3012, density 9 kg/m ³ ) was immersed in a phenol resin solution, taken out, and dried in an environment of 100 ° C for 31 minutes to form a resin foam for impregnated core material. The weight of the resin foam for core material which had been impregnated after drying was 67 g. Moreover, the ratio of the resin contained in the carbon fiber woven fabric and the resin foam for core materials was 64%.

Next, a prepreg having a porous sheet surface as an upper side and a resin material impregnated with a core material are sequentially laminated on a flat-shaped lower mold for extrusion molding which is previously coated with a release agent on the surface. The foam body and the prepreg having the porous sheet surface as the upper side were obtained to obtain a laminate. In other words, the laminated system is formed by laminating a fiber woven fabric, a porous sheet, a resin foam for a core material, a fiber woven fabric, and a porous sheet in this order from the bottom. This laminated body was placed on the lower mold for extrusion molding. In addition, the ratio of the thickness of the porous sheet which is a surface material to the total thickness of the porous sheet which becomes a core material, and the resin foam of the core material is 9%.

In the state in which the laminated body was placed on the lower mold for extrusion molding, the laminate was pressed at a temperature of 145 ° C by a top mold (flat plate shape) of 5 MPa for 8 minutes to perform compression and heating. The phenol resin is reacted and hardened under compression.

The heating of the laminate at this time is performed by a casting heater attached to the upper and lower extrusion dies. Further, the compression thickness of the laminated body was adjusted by providing a gap of 1.0 mm between the lower mold for extrusion molding and the upper mold. Thereafter, the lower mold and the upper mold are opened, and a fiber reinforcing material is laminated on both sides of the core material, and the surface material formed of the porous sheet is laminated on the fiber reinforcing material on one side and integrated. Strengthen the molded body.

With respect to the fiber-reinforced molded product of Example 2-15, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.40, the overall thickness is 1.0 mm, and the thickness of the core material is 0.48 mm. The compression ratio of the resin foam for the core material was calculated by using the thickness of the resin foam for core material before compression (7.5 mm) and the thickness of the core material (0.48 mm), and was calculated to be 1462% based on the formula of the compression ratio. Further, in the fiber-reinforced molded product of Example 2-15, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity, and it was 48 GPa.

‧Example 2-16

The prepreg obtained in the same manner as in the above-mentioned Example 2-15 was laminated on the lower mold (plate shape) for extrusion molding which was previously coated with a release agent on the surface, and sequentially laminated to have porosity. The sheet is a lower prepreg, a resin foam for impregnating the core material, and a prepreg having the porous sheet as the upper side to obtain a laminate. In other words, the laminated system has a porous sheet, a fiber woven fabric, a resin foam for a core material, a fiber woven fabric, and a porous sheet in this order from the bottom. This laminated body was placed on the lower mold for extrusion molding. In addition, the ratio of the total thickness of the porous sheet which becomes a surface material to the thickness of the resin foam for core materials was 19 %.

In the state in which the laminated body was placed on the lower mold for extrusion molding, the laminate was subjected to compression and heating for 8 minutes by applying a surface pressure of 5 MPa to the upper mold (flat plate shape) for extrusion molding at 145 ° C. The phenol resin is reacted and hardened under compression. The heating of the laminate at this time is performed by a casting heater attached to the upper and lower extrusion dies. Further, the compression thickness of the laminated body was adjusted by providing a gap of 1.0 mm between the lower mold for extrusion molding and the upper mold. Thereafter, the lower mold and the upper mold are opened, and a fiber-reinforced material is laminated on both sides of the core material, and a surface-formed material formed of a porous sheet is laminated on the fiber-reinforced material to form a fiber-reinforced molded body. .

With respect to the fiber-reinforced molded article of Example 2-16, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.40, the overall thickness is 1.0 mm, and the thickness of the core material is 0.48 mm. The compression ratio of the resin foam for the core material was calculated by using the thickness of the resin foam for core material before compression (7.5 mm) and the thickness of the core material (0.48 mm), and was calculated to be 1462% based on the formula of the compression ratio. Further, in the fiber-reinforced molded product of Example 2-16, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity, and it was 42 GPa.

‧Comparative Example 2-1

The thickness of the resin foam for the core material is 0.95 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. A fiber-reinforced molded product was obtained in the same manner as in Example 2-1 except that the ratio (the value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to be the surface material to the thickness of the resin foam for the core material was 42%.

With respect to the fiber-reinforced molded product of Comparative Example 2-1, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.28, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for the core material was 121% by the thickness of the resin foam for the core material before compression (0.95 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio. Further, in the fiber-reinforced molded product of Comparative Example 2-1, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. As a result of the measurement, the bending elastic modulus was 25 GPa (fiber direction), and the compression ratio was lower than that of the respective examples, so that the bending elastic modulus (rigidity) was low.

‧Comparative Example 2-2

The thickness of the resin foam for the core material is set to 30 mm, and the impregnation amount of the thermosetting resin in the resin foam for the core material is adjusted to make the resin contained in the entire resin foam of the fiber fabric and the core material. The fiber-reinforced molded product was molded in the same manner as in Example 2-1 except that the ratio (the value calculated by the formula (B1) of the resin ratio) was 65%. However, the film was not sufficiently compressed and only obtained. A molded body having a large thickness unevenness. In addition, the ratio of the thickness of the porous sheet which becomes a surface material to the thickness of the resin foam for core materials was 1 %.

The compression ratio in Comparative Example 2-2 is based on the case where the thickness of the core material obtained is assumed to be the same thickness (0.43 mm) as in Example 2-1, and the thickness of the resin foam for core material before compression is used. (30 mm), the result was 6877% based on the formula of the compression ratio, and since the compression ratio exceeded 5000%, Comparative Example 2-2 did not obtain a good molded body.

‧Comparative Example 2-3

As the resin foam for core material, a urethane resin foam containing an independent bubble (manufactured by Inoac Corporation, trade name: Thermax, density 30 kg/m ³ ) is processed to 200 × 300 × In the case of a resin having a thickness of 5 mm (a weight of 9 g) in place of the resin foam having continuous cells, the ratio of the resin contained in the fiber foam to the resin foam for the core material (calculated according to the formula (B1) of the resin ratio) A fiber-reinforced molded product was obtained in the same manner as in Example 2-8 except that the amount was 57%.

With respect to the fiber-reinforced molded product of Comparative Example 2-3, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.29, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material constituting the core material is calculated by using the thickness of the resin foam for core material before compression (5 mm) and the thickness of the core material (0.44 mm) according to the formula of the compression ratio. It is 1036%.

Further, in the fiber-reinforced molded product of Comparative Example 2-3, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. As a result of the measurement, the bending elastic modulus was 22 GPa (fiber direction), and since the foam of the closed cells was used for the core material, the thermosetting resin could not be uniformly dispersed and held in the core material as compared with the respective examples. For bending, the modulus of elasticity (rigid) is lower.

‧Comparative Example 2-4

In the same manner as in Example 2-1 except that the resin ratio (the value calculated by the formula (B1) of the resin ratio) contained in the entire resin foam of the core material was 45%. Fiber reinforced molded body. With respect to the fiber-reinforced molded article of Comparative Example 2-4, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.28, the overall thickness is 0.9 mm, and the thickness of the core material is 0.43 mm. The compression ratio of the resin foam for a core material was 2225% based on the thickness of the resin foam for the core material before compression (10 mm) and the thickness of the core material (0.43 mm), based on the formula of the compression ratio.

Further, in the fiber-reinforced molded product of Comparative Example 2-4, the bending elastic modulus (JIS K7074-1988 A method) was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus was 27 GPa (fiber direction), and since the resin ratio was too low, the thermosetting resin contained was less than that of the respective examples, and the flexural modulus (rigidity) was low. .

‧Comparative Example 2-5

The fiber-reinforced molded product was molded in the same manner as in Example 2-1 except that the ratio of the resin contained in the fiber foam to the resin foam for the core material was 85%, but the resin ratio was too high. Therefore, the thermosetting resin contained in the resin foam for the fiber woven fabric and the core material is too large to be sufficiently compressed, and only a molded body having a large thickness unevenness is obtained.

‧Comparative Example 2-6

As the resin foam for core material, a urethane resin foam containing an independent bubble (manufactured by Inoac Corporation, trade name: Thermax, density 30 kg/m ³ ) is processed to 200 × 300 × A resin foam having continuous bubbles was replaced by a thickness of 1.4 mm (2.5 g by weight). Since the foam is an independent bubble, the thermosetting resin cannot be impregnated, so that the fiber fabric is impregnated with the thermosetting resin.

The weight of the fiber fabric which had been impregnated after drying was adjusted to 37 g, and the ratio of the resin contained in the fiber fabric to the thermosetting foam was 65%. Further, a fiber-reinforced molded product of Comparative Example 2-6 was obtained in the same manner as in Example 2-8.

With respect to the fiber-reinforced molded product of Comparative Example 2-6, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.28, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for a core material was calculated by using the thickness of the resin foam for core material before compression (1.4 mm) and the thickness of the core material (0.44 mm), and was calculated to be 218% based on the formula of the compression ratio. Further, in the fiber-reinforced molded product of Comparative Example 2-6, the bending elastic modulus (JIS K7074) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 18 GPa (fiber direction).

‧Comparative Example 2-7

A urethane resin foam containing an independent bubble (manufactured by Inoac Corporation, trade name: Thermax, density 30 kg/m ³ ) was processed into 200 × 300 × thickness 2.3 mm (weight 4.1 g) The resin foam for the core material is adjusted so that the weight of the fiber fabric impregnated after drying is 38 g, and the ratio of the resin contained in the fiber foam to the resin foam for the core material is adjusted. Become 65%. Further, a fiber-reinforced molded product was obtained in the same manner as in Comparative Example 2-6.

With respect to the fiber-reinforced molded product of Comparative Example 2-7, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.29, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was 422% as a function of the compression ratio using the thickness of the resin foam for core material before compression (2.3 mm) and the thickness of the core material (0.44 mm). Further, with respect to the fiber-reinforced molded product of Comparative Example 2-7, the bending elastic modulus (JIS K7074) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 20 GPa (fiber direction).

‧Comparative Example 2-8

A urethane resin foam containing an independent bubble (manufactured by Inoac Corporation, trade name: Thermax, density 30 kg/m ³ ) was processed into 200 × 300 × thickness 3 mm (weight 5.4 g) The resin foam for the core material is adjusted so that the weight of the fiber fabric which has been impregnated after drying is 39 g, and the resin ratio of the fiber woven fabric and the resin foam for the core material as a whole is adjusted. Become 65%. Further, a fiber-reinforced molded product was obtained in the same manner as in Comparative Example 2-6.

With respect to the fiber-reinforced molded article of Comparative Example 2-8, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.29, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was 581% as a function of the compression ratio using the thickness (3 mm) of the resin foam for core material before compression and the thickness of the core material (0.44 mm). Further, with respect to the fiber-reinforced molded product of Comparative Example 2-8, the bending elastic modulus (JIS K7074) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 21 GPa (fiber direction).

‧Comparative Example 2-9

A urethane resin foam containing an independent bubble (manufactured by Inoac Corporation, trade name: Thermax, density 30 kg/m ³ ) was processed into 200 × 300 × thickness 4 mm (weight: 7.2 g) The resin foam for the core material is adjusted so that the weight of the fiber fabric impregnated after drying is 41 g, and the resin ratio of the fiber woven fabric and the resin foam for the core material as a whole is adjusted. Become 65%. Further, a fiber-reinforced molded product was obtained in the same manner as in Comparative Example 2-6.

With respect to the fiber-reinforced molded article of Comparative Example 2-9, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was 809% as a function of the compression ratio using the thickness (4 mm) of the resin foam for core material before compression and the thickness of the core material (0.44 mm). Further, in the fiber-reinforced molded product of Comparative Example 2-9, the bending elastic modulus (JIS K7074) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 21 GPa (fiber direction).

‧Comparative Example 2-10

A urethane resin foam containing an independent bubble (manufactured by Inoac Corporation, trade name: Thermax, density 30 kg/m ³ ) was processed into 200 × 300 × thickness 5 mm (weight: 9 g) The resin foam for the core material is adjusted so that the weight of the fiber fabric impregnated after drying is 43 g, and the ratio of the resin contained in the fiber foam to the resin foam for the core material is adjusted. Become 65%. Further, a fiber-reinforced molded product was obtained in the same manner as in Comparative Example 2-6.

With respect to the fiber-reinforced molded product of Comparative Example 2-10, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity is 1.30, the overall thickness is 0.9 mm, and the thickness of the core material is 0.44 mm. The compression ratio of the resin foam for the core material was calculated by the formula of the compression ratio using a thickness (5 mm) of the resin foam for core material before compression and a thickness of the core material (0.44 mm), and found to be 1036%. Further, in the fiber-reinforced molded product of Comparative Example 2-10, the bending elastic modulus (JIS K7074) was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 22 GPa (fiber direction).

The compression ratio, the resin ratio, the specific gravity, the thickness, and the flexural modulus in each of the examples and the comparative examples are shown in Table 2.

In Table 2, in the examples 2-1 to 2-5 and the examples 2-12 to 2-14 in which the resin foam for core material and the fiber fabric were the same type and the resin ratio was the same, the compression ratio was higher. The Example 2-4, which is 225% lower, has a lower flexural modulus (rigidity) than the other examples, and on the other hand, the specific gravity of Examples 2-5 having a higher compression ratio of 4900% is improved. As described above, when the compression ratio is lowered, the bending elastic modulus (rigidity) tends to decrease. On the other hand, when the compression ratio is increased, the specific gravity tends to increase. In such terms, the compression ratio is preferably from 200 to 5000%, more preferably from 1000 to 2600%.

Further, in Examples 2-1, 2-7 to 2-9, and Comparative Example 2-4 in which the resin foam for core material and the fiber fabric were composed of the same kind and the compression ratio was the same, the resin ratio was 45%. The flexural modulus of Comparative Example 2-4 was a lower 27 GPa, whereas the flexural modulus of Example 8 having a resin ratio of 66% was a higher 50 GPa, so that it was found that if the resin ratio was increased Then, the bending elastic modulus (rigidity) is improved.

Further, the compression ratio was substantially the same as that of Examples 2-1, 2-7 to 2-9, and Comparative Example 2-4, and the specific gravity of Example 2-6 in which the resin ratio was 74% higher was 1.45. The specific gravity of Comparative Example 2-4 having a resin ratio of 45% was 1.28, and the specific gravity of Example 2-7 having a resin ratio of 51% was 1.30. Thus, it was found that the specific gravity tends to increase as the resin ratio increases. In these respects, the resin ratio is preferably from 50 to 80%, more preferably from 55 to 70%.

Comparative Example 2-3 and Comparative Examples 2-6 to 2-10 in which the resin foam for core material contains the independent bubble, and the resin foam for the core material include the embodiment having the continuous bubble and the other comparative examples. The bending elastic modulus is extremely reduced. In addition, the ratio of the total thickness of the porous sheet before the compression of the surface material to the total thickness of the resin foam and the porous sheet for the core material before compression is 2% to 29%. In Examples 2-1 to 2-16, the bending elastic modulus was larger than Comparative Example 2-1 in which the ratio was 42%.

Further, when Examples 2 to 15 in which only one surface of the fiber-reinforced molded article was covered with a porous sheet and the both sides of the fiber-reinforced molded article were covered with a porous sheet, the examples were confirmed. The flexural modulus of 2-16, although reduced compared to Examples 2-15, still shows a higher flexural modulus. In other words, even if the porous sheet having the continuous cells is disposed on both surfaces to improve the design, the bending elastic modulus (rigidity) can be sufficiently maintained. Therefore, according to the fiber-reinforced molded article of the present invention, both aesthetics and strength can be achieved at the same time.

As described above, the product of the present invention is suitable for use as a casing for a mobile device such as a notebook computer, etc., which has a good appearance and a peeling coating film when it is lightweight, thin-walled, and highly rigid. .

In the present invention, the thermosetting resin may be impregnated into the porous sheet used in the lamination step in advance. In this case, even if the compression ratio in the subsequent compression heating step is small, the thermosetting resin can be disposed on the surface to form a uniform resin layer, and the surface smoothness of the fiber-reinforced molded article becomes good.

The present invention has been described in detail above with reference to the specific embodiments thereof. It is understood that various changes and modifications can be made without departing from the scope and spirit of the invention.

The present application is based on a Japanese patent application filed on August 30, 2010 (Japanese Patent Application No. 2010-191850), and a Japanese patent application filed on November 4, 2010 (Japanese Patent Application No. 2010-247288) The contents thereof are incorporated herein by reference.

[Industrial availability]

The fiber-reinforced molded article of the present invention has a smooth surface due to a step formed by a gap portion of the woven fabric of the fiber woven fabric constituting the fiber-reinforced material, and is filled with a thermosetting resin impregnated in the porous sheet and hardened. . Therefore, the fiber-reinforced molded product of the present invention has high rigidity by using a fiber reinforcing material, and has a good appearance and adhesion to a coating by a smooth surface. Moreover, according to the method for producing a fiber-reinforced molded article of the present invention, a fiber-reinforced molded article having high rigidity and good appearance can be easily obtained.

10. . . Fiber reinforced molded body

10A. . . Laminated body

10B. . . Laminated body

10C. . . Laminated body

10D. . . Laminated body

10E. . . Laminated body

11. . . Core

11A. . . Core member

11B. . . Thermosetting resin

11C. . . Immersed core material member

20A. . . Prepreg

twenty one. . . Fiber reinforcement

21A. . . Fiber fabric

21B. . . Thermosetting resin

21C. . . Immersed fiber fabric

25. . . Surface material

25A. . . Porous sheet

27. . . Coating film

31. . . Lower die

33. . . Upper mold

215. . . Fiber overlap

216. . . gap

221. . . Cross fiber

222. . . Longitudinal fiber

Fig. 1 is a cross-sectional view showing a fiber-reinforced molded product according to a first embodiment of the present invention.

Fig. 2 is a cross-sectional view showing the fiber-reinforced molded body shown in Fig. 1 in which a coating film is provided on the surface of the surface material.

3(3-1) to 3(3-3) are views showing the steps of the production method of the first (1)th embodiment of the present invention.

4(4-1) to 4(4-3) are views showing the steps of the manufacturing method of the first (2)th embodiment of the present invention.

Fig. 5 (5-1) to (5-3) are views showing the steps of the production method of the first (3)th embodiment of the present invention.

Fig. 6 (6-1) to (6-3) are views showing the steps of the production method of the first (4)th embodiment of the present invention.

7(7-1) to 7(7-3) are views showing the steps of the manufacturing method of the modification of the first to (4)th embodiment of the present invention.

Fig. 8(a) is a plan view of the fiber fabric, and Fig. 8(b) is a sectional view thereof.

10. . . Fiber reinforced molded body

11. . . Core

twenty one. . . Fiber reinforcement

25. . . Surface material

Claims (9)

A method for producing a fiber-reinforced molded article, which comprises producing a core material comprising a core material member, a fiber reinforcing material laminated on at least one surface of the core material and having a fiber fabric, and laminating the fiber reinforcement A method for producing a fiber-reinforced molded article having a surface material of a porous sheet, the method comprising the steps of: impregnating a thermosetting resin to at least the member for core material and at least the fiber fabric And a laminating step of sequentially laminating the fiber fabric and the porous cells having continuous cells of 8 to 80/25 mm and having a thickness of 0.4 to 3.0 mm on at least one surface of the core member. And a compression and heating step of heating the thermosetting resin to the core member by heating the member for the core material, the fiber woven fabric, and the porous sheet while being compressed. The fiber woven fabric and the porous sheet are cured to integrate the core material, the fiber reinforced material, and the surface material, and the fiber reinforced material In the impregnation step, the thermosetting resin is impregnated into the core member by the resin ratio R defined by the following formula (B1) in the range of 50 to 80%. In the above laminating step, on the other side of the member for core material In the above-described compression and heating step, the above-mentioned thermosetting property is obtained in a state where the core material member is compressed so that the compression ratio C defined by the following formula (A1) is in the range of 200 to 5000%. The resin is cured, and the flexural modulus of the fiber-reinforced molded product is 30 GPa or more, C = (Tb - Ta) / Ta × 100% (A1) (Ta: thickness of the member for core material after compression, Tb: before compression Thickness of member for core material, C: compression ratio) R = (Wb - Wa) / Wb × 100% (B1) (Wa: total weight of member for core material, fiber fabric, porous sheet, Wb: impregnation The total weight of the core member, the fiber woven fabric, and the porous sheet after the thermosetting resin, R: resin ratio). The method for producing a fiber-reinforced molded product according to claim 1, wherein the porous sheet comprises the porous sheet of the urethane resin foam from which the pore-forming film is removed. The method for producing a fiber-reinforced molded article according to claim 1, wherein the thermosetting resin containing the same material is impregnated into both the core member and the fiber fabric in the impregnation step. The method for producing a fiber-reinforced molded article according to claim 1, wherein in the step of laminating, a prepreg in which the fiber fabric impregnated with the thermosetting resin and the porous sheet are laminated to form the fiber fabric The prepreg is laminated on the core member for contact with the core member. The method for producing a fiber-reinforced molded article according to claim 1, wherein in the stacking step, two prepregs having the fiber fabric impregnated with the thermosetting resin and the porous sheet are formed to make one The fiber fabric of the prepreg is in contact with the core member, and the porous sheet of the other prepreg is brought into contact with the core member on both sides of the core member. The above prepreg is laminated on the upper layer. The method for producing a fiber-reinforced molded article according to claim 1, wherein the compression ratio of the member for core material is set to 1000 to 2600%. The method for producing a fiber-reinforced molded article according to claim 1, wherein in the stacking step, two prepregs having the fiber fabric impregnated with the thermosetting resin and the porous sheet are formed so as to be The fiber woven fabric is placed in contact with the core member, and the prepreg is laminated on both surfaces of the core member. A fiber-reinforced molded product comprising a core material containing a core material member having continuous cells, a fiber reinforcing material laminated on both surfaces of the core material and having a fiber fabric, and a fiber reinforced material laminated on the fiber reinforcing material a surface material of the porous sheet, and the core material, the fiber reinforcing material, and the surface material are integrated by a thermosetting resin; The core material is obtained by impregnating the above-mentioned core material member with the thermosetting resin and curing the thermosetting resin in a state where the core material member is compressed, and is defined by the following formula (A1). When the compression ratio C is in the range of 200 to 5000%, the resin ratio R defined by the following formula (B1) of the thermosetting resin is in the range of 50 to 80%, and the flexural modulus of the fiber-reinforced molded article is 30 GPa or more. C=(Tb-Ta)/Ta×100% (A1) (Ta: thickness of member for core material after compression, Tb: thickness of member for core material before compression, C: compression ratio) R=(Wb- Wa)/Wb×100% (B1) (Wa: total weight of member for core material, fiber woven fabric, and porous sheet, Wb: member for core material, fiber fabric, and porous sheet after impregnating thermosetting resin Total weight, R: resin ratio). A method for producing a fiber-reinforced molded article, comprising: producing a core material comprising a member for core material having continuous cells, a fiber reinforcing material laminated on both surfaces of the core material and having a fiber fabric, and laminating a method for producing a fiber-reinforced molded article comprising a surface material of a porous sheet having continuous cells on at least one surface of the fiber-reinforced material; the method of manufacturing comprising the step of impregnating a thermosetting resin into the above Core material structure And at least one of the fiber fabrics; a laminating step of laminating the fiber fabric on both sides of the core member, and laminating the porous sheet on at least one side of the laminated fiber fabric; and compressing a heating step of heating the thermosetting resin to the core member, the fiber fabric, and the like by heating the member for the core member, the fiber fabric, and the porous sheet while compressing The core sheet, the fiber reinforcing material, and the surface material are integrated in the porous sheet, and the impregnation step in the impregnation step is 50 to 80% by the resin ratio R defined by the following formula (B1). In the above-described range, the compression in the compression heating step is performed such that the compression ratio C defined by the following formula (A1) is 200 to 5000%, and C = (Tb - Ta) / Ta × 100% (A1) (Ta: thickness of member for core material after compression, Tb: thickness of member for core material before compression, C: compression ratio) R = (Wb - Wa) / Wb × 100% (B1) (Wa: core Total weight of material members, fabrics, and porous sheets, Wb: After immersion of the core material a thermosetting resin member, the fiber fabric, the total weight of the porous sheet, R: resin ratio).